The only thing that can make layer picking more effective is to pair it with pallet flow rack. Pallet flow lanes distribute single SKU pallets to the pick aisle for easy picking AND reverse flow lanes secure empty pallets in place for palletizing and then release them to the opposite aisle for extraction. This seamless symphony of mixed technologies provides the processing boost that facilities need and reduce reliance on labor.
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Read blog excerpt below:
Floor-Mounted Pallet Flow Easily Adapts for Forklift or Robotic Arm Layer Picking
Our warehouses and distribution centers are facing severe labor and demand challenges. More than just lending a hand, layer picking can give them a whole arm of highly efficient, accurate picking support. Full case layers can be picked and deposited with a layer pick arm to build mixed SKU rainbow pallets exponentially faster than manual case picking. Layer picking is ideal for high-volume staging or mixing centers, picking more than 1000 layers per day from between 50-500 SKUs.
The layer pick separator is the secret ingredient to make it all work. Each pallet flow lane is equipped with a layer pick separator that isolates the pallet at the pick aisle to enable the layer pick arm to secure one or more case layers. The pallet separator holds the rear pallets away from the pick aisle pallet until the empty pallet is ultimately extracted from the lane. Once the empty pallet is removed, the rear pallets automatically advance to fill in the pick face.
Installing Pallet Flow Lanes & Layer Pick Separator
Pallet flow lanes that feed the pick face pitch towards the pick aisle. The reverse flow lanes pitch to the opposite aisle so that when the rainbow pallet is complete, it can flow away from the pick aisle and be positioned for extraction. The reverse flow lanes can fit in-between or at the end of the flow lanes wherever it is most efficient for your application.
Faster, More Efficient Layer Picking from Pallet Flow Rack
• Equip for forklift or robotic arm layer picking
• Automatic pick face replenishment
• Ready reserve pallets
• Reduced congestion
• Save valuable labor costs & equipment expense
Layer Picking with Forklift Attachment or Robotic Picking Arm
The process of building a rainbow mixed SKU pallet with a layer pick attachment from pallet flow lanes takes only a few steps. It is a safe and productive way to meet demand and order processing goals.
1. The forklift or robotic arm is guided along the layer pick aisle to secure one or more layers at a time from the stocked flow lanes.
2. The layer picker delivers the cases to the reverse flow lane and the waiting empty pallet.
3. The layer picker continues to pick case layers until the rainbow pallet is complete.
4. The completed pallet is released to flow to the opposite aisle for extraction. In a forklift application, the operator uses a remote control to release the pallet. In a robotic arm application, the pallet release is programmed automatically.
5. The layer pick device picks up an empty pallet and places it into the reverse flow lane to begin the process again.
Expert Gravity Flow Storage Solutions
Integrating gravity flow rack with semi-automated or automated warehouse systems takes an expert, and no one knows flow rack like the team at Mallard. We are ready to provide customized design ideas, engineering support, and top-notch customer service. In addition, we offer in-house or on-site testing to confirm your pallet flow lane design meets your expectations before you purchase. Call our gravity flow rack experts today for a free consultation.
