What Pallet Types Are Suitable for Pallet Flow Racking?

Pallet flow racking is a high-density FIFO storage system that uses gravity rollers to move pallets from the loading side to the picking side.

Because pallets travel directly on the roller lanes, the pallet type, bottom structure, dimensions, weight and condition all affect how smoothly the system operates.

Choosing a suitable pallet is therefore an important part of pallet flow rack design. A pallet that performs well on standard selective racking may not always move reliably on gravity rollers.

This article explains which pallet types are suitable for pallet flow racking and what buyers should check before selecting a system.

Why Pallet Type Matters in Pallet Flow Racking

Unlike conventional pallet racks, pallet flow systems depend on controlled pallet movement.

The pallet must:

Enter the flow lane correctly
Maintain stable contact with the rollers
Move smoothly under gravity
Stay aligned during travel
Stop safely at the picking position

If the pallet base is uneven, damaged or incompatible with the roller layout, problems such as unstable movement, jamming or excessive impact may occur.

For this reason, pallet information should always be confirmed before finalizing the rack design.

1. Wooden Pallets

Wooden pallets are commonly used with pallet flow racking because they are widely available and suitable for many warehouse applications.

However, not every wooden pallet is automatically suitable.

Important factors include:

Bottom board arrangement
Board thickness
Pallet flatness
Nail position
Overall pallet condition
Maximum pallet weight

The pallet should provide consistent contact with the rollers throughout the flow lane.

Damaged boards, protruding nails or warped pallet bases may affect movement and should be avoided.

2. Plastic Pallets

Plastic pallets can also be used in pallet flow systems when their base structure is compatible with the roller configuration.

Their advantages may include:

Consistent dimensions
Smooth bottom surfaces
Good resistance to moisture
Easy cleaning
Stable performance in hygienic environments
Plastic pallets are often considered for:
Food warehouses
Beverage storage
Pharmaceutical facilities
Cold storage
Clean industrial environments

However, some plastic pallets have molded bottom structures that may not provide continuous contact with the rollers.

The pallet base should therefore be checked before rack design.

3. Steel Pallets

Steel pallets may be suitable for heavy-duty or industrial pallet flow applications.

They are commonly used when:

Pallet loads are heavy

Durability is important

The warehouse handles industrial materials

Reusable pallet systems are required

Because steel pallets can be heavier than wooden or plastic pallets, the flow lane, roller capacity, damping devices and braking system must be designed accordingly.

Heavy pallets may also require more careful speed control.

4. Two-Way and Four-Way Entry Pallets

Pallet entry direction can influence how the pallet contacts the rollers.

A two-way entry pallet may have a different underside structure from a four-way entry pallet.

Before design, buyers should confirm:

Which side enters the rack
Pallet fork opening direction
Bottom board orientation
Roller contact direction

This helps engineers determine the most suitable lane and roller arrangement.

Pallet flow racking system for high-density FIFO warehouse storage

Which Pallet Bottom Structures Work Best?

For pallet flow racking, the underside of the pallet is often more important than the top surface.

A suitable pallet usually has:

Stable runner or board contact
Consistent bottom height
No excessive deformation
Sufficient structural strength
Clear and predictable roller contact points

Pallets with irregular feet, broken runners or large unsupported gaps may require special consideration.

In some cases, roller spacing can be customized to match the pallet base structure.

Pallet Size and Weight Requirements

Pallet dimensions and weight directly influence pallet flow rack design.

Important information includes:

Pallet length
Pallet width
Pallet height
Maximum loaded weight
Load distribution
Number of pallets per lane

The pallet should also be evaluated in its fully loaded condition, not only when empty.

A pallet carrying unevenly distributed goods may behave differently on the flow lane.

For more information on system design, see: How to Choose the Right Pallet Rack Depth for Your Warehouse

Pallet Condition Is Also Important

Even a suitable pallet type may cause problems if it is damaged.

Before pallets enter the system, warehouse operators should check for:

Broken boards
Cracked plastic
Bent metal components
Missing runners
Protruding nails
Excessive deformation
Unstable loads

Regular pallet inspection helps maintain more consistent flow performance.

How Roller Configuration Matches the Pallet

Pallet flow lanes are not one-size-fits-all.

The roller arrangement should be matched to:

Pallet base design
Pallet weight
Lane depth
Required flow speed
Number of pallets per lane

Typical system components may include:

Gravity rollers
Guide rails
Damping devices
Pallet separators
Safety stops

For heavier pallets or deeper lanes, additional speed-control components may be required.

This topic will be covered in more detail in our next article:

How Pallet Flow Rack Braking Systems Control Pallet Speed

Wooden vs Plastic vs Steel Pallets

Pallet Type	Main Advantages	Main Considerations
Wooden Pallet	Common, economical, widely available	Must be flat and undamaged
Plastic Pallet	Consistent size, moisture resistant	Bottom structure must match rollers
Steel Pallet	Durable and suitable for heavy loads	Higher weight requires stronger flow control
Custom Pallet	Can be designed for specific applications	Roller layout should be matched carefully

There is no single pallet type that is always best.

The correct choice depends on the warehouse application, stored goods, pallet weight and flow lane design.

Pallet Flow Racking for Cold Storage

Cold storage is a common application for pallet flow racking because high-density storage helps maximize expensive refrigerated space.

In cold environments, pallet selection should also consider:

Temperature resistance
Moisture exposure
Material durability
Surface condition
Pallet dimensional stability

Plastic and specially treated pallets may be suitable in some cold storage applications, while wooden pallets remain widely used where appropriate.

For high-density refrigerated storage, pallet compatibility should be reviewed together with the complete rack design.

Common Pallet-Related Problems in Flow Racks

Several pallet problems can affect flow performance:

Pallets Stop Mid-Lane

Possible causes include damaged pallet bases, insufficient roller contact or unsuitable lane design.

Pallets Move Too Fast

This may occur when pallet weight, lane inclination and braking configuration are not properly matched.

Pallets Become Misaligned

Guide rails or pallet dimensions may need adjustment.

Pallets Do Not Release Smoothly

Pallet separators or front picking components may require different configuration.

These issues are usually easier to prevent during system design than to correct after installation.

What Information Should Buyers Provide?

To evaluate whether your pallets are suitable for pallet flow racking, provide:

Pallet photos
Pallet length and width
Pallet height
Maximum loaded weight
Bottom structure photos
Forklift entry direction
Number of pallets per lane
Required FIFO operation
Warehouse dimensions
Storage temperature, if applicable

With this information, the rack supplier can evaluate the roller layout and flow configuration more accurately.

How JINHUI RACK Designs Pallet Flow Systems

JINHUI RACK provides customized pallet flow rack solutions according to pallet specifications and warehouse conditions.

Our engineering team considers:

Pallet type and bottom structure
Maximum pallet weight
Lane depth
Required pallet positions
FIFO workflow
Roller configuration
Speed-control requirements
Forklift operation
Warehouse height
Cold-storage conditions

Based on this information, we can recommend a suitable pallet flow configuration and prepare layout drawings for project evaluation.

Conclusion

The right pallet is essential for reliable pallet flow rack operation.

Wooden, plastic and steel pallets can all be suitable, but their bottom structure, dimensions, weight and condition must match the roller system.

Before selecting a pallet flow rack, buyers should provide complete pallet specifications and photos so the system can be designed around the actual load.

A correctly matched pallet and roller configuration helps improve flow reliability, warehouse efficiency and long-term system performance.