Shelving & Picking

Quote-led storage system • Storage study recommended

Shrusti Flow Racks

Shrusti Flow Racks is a gravity carton-flow picking rack solution for high-volume case/carton order picking. It provides lane-front carton only with high storage density and is planned around manual load/pick; gravity moves cartons.

DensityHighAccessLane-front carton onlyHandlingManual load/pick; gravity moves cartons

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Product overview

Gravity carton-flow picking rack for high-volume case/carton order picking.

Shrusti Flow Racks is designed for high-volume case/carton order picking. Cartons or bins are loaded into inclined roller lanes from the replenishment side and move forward under gravity to the picking face. The oldest unit reaches the operator first. The system balances high storage density with lane-front carton only and uses guaranteed fifo (gravity-enforced) stock flow. Selection starts with the confirmed load unit, inventory profile, available height, floor layout and handling method. Final structural ratings, dimensions and accessories are stated in the Shrusti quotation and approved layout.

How it works

Cartons or bins are loaded into inclined roller lanes from the replenishment side and move forward under gravity to the picking face. The oldest unit reaches the operator first.

Key features

Dedicated carton-flow lanes with separate load and pick faces
Storage density: High
Storage access: Lane-front carton only
Stock rotation: Guaranteed FIFO (gravity-enforced)
Handling method: Manual load/pick; gravity moves cartons
Load profile: Cartons, boxes, crates
More lanes and levels can be added when carton dimensions, weight, roller selection and frame ratings remain compatible.
Slightly inclined lanes of wheels or rollers move cartons by gravity from the replenishment end to the picking end
Separate replenishment and picking aisles keep restocking and picking activity from interfering with each other

Benefits

Space utilisation: High density for the documented inventory profile.
Accessibility: Lane-front carton only.
Inventory flow: Guaranteed FIFO (gravity-enforced).
Operational fit: Designed for high-volume case/carton order picking.
Handling compatibility: Planned around manual load/pick; gravity moves cartons.
Expansion: More lanes and levels can be added when carton dimensions, weight, roller selection and frame ratings remain compatible.
Safety: Verify carton/bin quality, roller pitch, lane incline, separators, end stops, ergonomic picking height and replenishment/picking separation.
Inventory control: Guarantees product turnover by enforcing loading-order rotation along each lane.
Operational efficiency: Reduces order-preparation time and increases the number of SKU references available at the pick face
Space utilization: Described as increasing storage capacity relative to static shelving for the same footprint

Technical specifications

Published configuration framework.

Only product information supported by the catalogue is shown. Final dimensions and structural ratings are stated in the approved quotation and layout.

Flow Racks technical specifications
Product family	Shelving & Picking
Storage type	Gravity carton-flow picking rack
Load capacity	Project-specific; final load capacity is stated in the approved structural layout.
Bay configuration	Dedicated carton-flow lanes with separate load and pick faces
Storage depth	Multi-deep gravity lanes; depth is project-specific
Frame / structure height	Project-specific; final frame height follows the approved facility layout.
Beam / shelf / tier levels	Adjustable or project-specific levels based on the load and inventory profile.
Bay width	Sized to the confirmed load unit and handling method in the approved layout.
Bay depth	Defined by the storage method and load geometry in the approved layout.
Shelf load capacity	Project-specific; no fixed shelf-load figure is published.
Bay load capacity	Project-specific; stated in the approved structural design.
Upright / structural section	Selected to the confirmed load, height and bay arrangement in the structural design.
Material construction	Steel structural components are used; grade and section are confirmed in the technical offer.
Coating / finish	Finish is selected in the quotation for the operating environment.
Storage accessibility	Lane-front carton only
Storage density	High
Stock rotation	Guaranteed FIFO (gravity-enforced)
Handling method	Manual load/pick; gravity moves cartons
Expansion capability	More lanes and levels can be added when carton dimensions, weight, roller selection and frame ratings remain compatible.
Safety provisions	Verify carton/bin quality, roller pitch, lane incline, separators, end stops, ergonomic picking height and replenishment/picking separation.
Suitable load units	Cartons, boxes, crates
Facility compatibility	High-volume case/carton order picking
Customization options	Lane width/depth, roller pitch, guides, separators, presentation angle, pick face, level count and supporting rack.

Applications and warehouse use cases

Match the system to the inventory and operating method.

Applications

Primary application: High-volume case/carton order picking.
Typical load profile: Cartons, boxes, crates.
Preferred handling method: Manual load/pick; gravity moves cartons.
the product profile positions carton flow racks broadly across mass-consumption product warehouses, pharmaceuticals or cosmetics, and IT and automotive-industry parts, and notes the system is also used in assembly-line buffer or intermediate storage between two working points.
Typical operational scenarios: Best where order-picking volume and line count are high enough to justify a dedicated flow-rack pick face with guaranteed rotation.
Industry applications: Mass-consumption product distribution, pharmaceuticals and cosmetics, and IT and automotive-parts distribution.

Warehouse use cases

Facilities managing high-volume case/carton order picking.
Layouts requiring lane-front carton only.
Operations using manual load/pick; gravity moves cartons.
Inventory flows based on guaranteed fifo (gravity-enforced).

Industry suitability

Flow Racks industry suitability
Manufacturing	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
Automotive	Strong fitStrong fit where the operation matches this system's documented load, access and inventory profile.
Engineering	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
FMCG	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
Retail	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
E-Commerce	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
Pharmaceuticals	Strong fitStrong fit where the operation matches this system's documented load, access and inventory profile.
Food Processing	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
Textiles	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
Chemicals	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
Logistics & 3PL	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
Cold Storage	Application-dependentApplication-dependent; confirm the load unit, SKU profile, handling method and facility before selection.
Industrial Distribution	Strong fitStrong fit where the operation matches this system's documented load, access and inventory profile.

Safety, customisation and support

Define the interfaces before installation.

Safety benefits

Verify carton/bin quality, roller pitch, lane incline, separators, end stops, ergonomic picking height and replenishment/picking separation.
Project-specific load ratings and clear operating limits are stated in the approved layout and handover documentation.
Installation planning should separate equipment routes, pedestrian access and service clearances where applicable.

Customization options

Lane width/depth
roller pitch
guides
separators
presentation angle
pick face
level count and supporting rack.

Installation & support

Storage study and requirement capture
Layout and configuration development
Structural selection and project quotation
Supply and installation coordination
Handover, operator guidance and documentation
AMC, preventive maintenance and inspection support

Maintenance guidance

Inspect rollers, guides, separators, end stops, lane alignment and carton condition to preserve smooth flow.
Do not modify levels, bays, lanes or platforms beyond the approved configuration without engineering review.
Record impact damage, deformation or missing components and isolate affected positions until reviewed.

Buying guide

Choose from the operating requirement, not the product name.

Who should buy it: Operations with high-volume case/carton order picking.
Inventory profile: Cartons, boxes, crates with guaranteed fifo (gravity-enforced) stock flow.
Access and density: Choose this system when lane-front carton only and high density match the operating priority.
Handling equipment: Confirm compatibility with manual load/pick; gravity moves cartons before fixing aisle, bay or lane dimensions.
Selection criterion: Confirm lane depth and carton weight/dimension range.
Expansion: Review the five-year SKU, capacity and building-growth plan before finalising row lengths, levels or platform coverage.
Budget: Commercial pricing is project-specific and follows the approved layout, structural ratings, accessories and installation scope.
Buyers should confirm carton weight and dimension ranges against the lane's roller specification, plan separate replenishment and picking aisles into the layout, and consider pick-to-light integration if picking accuracy and speed are priorities for a high-line-count operation.

Comparison table

Compare adjacent systems.

Attribute	Long Span Shelve Racks	Flow Racks	Pallet Live Storage
Storage density	Medium	High	High
Accessibility	Every shelf position	Lane-front carton only	Lane-front pallet only
Load capacity	Project-specific quotation	Project-specific quotation	Project-specific quotation
Cost level	Project-specific quotation	Project-specific quotation	Project-specific quotation
Flexibility	Add-on bays and adjustable beam levels support straightforward extension and reconfiguration.	More lanes and levels can be added when carton dimensions, weight, roller selection and frame ratings remain compatible.	More lanes and levels can be added where the pallet profile, braking design and structure remain consistent.
Best use case	Wide SKU range, hand-picked	High-volume case/carton order picking	Rotation-critical, perishable goods
Warehouse type	Adjustable manual-picking shelving	Gravity carton-flow picking rack	Gravity-fed FIFO pallet storage
Ideal industry	General industrial, engineering, and light manufacturing operations with a wide SKU range	Mass-consumption product distribution, pharmaceuticals and cosmetics, and IT and automotive-parts distribution.	Food and beverage, pharmaceuticals, and other operations with date-coded or perishable stock

Product FAQs

Questions buyers ask before a storage quotation.

What are carton flow racks?

They are gravity-fed shelving systems using inclined roller or wheel lanes, where cartons loaded at the replenishment end slide down to the picking end at the opposite aisle — used for high-volume case and box picking.

How do carton flow racks improve order picking?

Shrusti states they guarantee product turnover, increase the number of SKU references available at the front of the rack, and reduce order-preparation time by keeping pick faces continuously replenished.

Can carton flow racks work with pick-to-light systems?

Yes — the product profile notes the possibility of fitting a pick-to-light system, a screen that provides order details to the picker, alongside the flow rack.

What industries use carton flow racks?

Shrusti names mass-consumption product warehouses, pharmaceuticals and cosmetics, and IT and automotive-industry parts distribution.

Do carton flow racks need separate aisles?

Yes — the system requires a loading/replenishment aisle at one end of the lane and a picking aisle at the other, so restocking and picking activity don't interfere with each other.

How are carton flow racks different from pallet live storage?

Both use gravity-fed, FIFO-style flow lanes, but carton flow racks operate at the carton/case/box level for order picking, while pallet live storage operates at the full pallet level for bulk storage.

What is Flow Racks?

Flow Racks is a gravity carton-flow picking rack system. Cartons or bins are loaded into inclined roller lanes from the replenishment side and move forward under gravity to the picking face. The oldest unit reaches the operator first.

What inventory profile suits Flow Racks?

It is best suited to high-volume case/carton order picking, using cartons, boxes, crates.

What storage density does Flow Racks provide?

The catalogue classifies its storage density as high. Actual capacity depends on the approved layout and load profile.

How accessible are stored goods in Flow Racks?

Storage access is described as lane-front carton only.

What handling equipment is used with Flow Racks?

The documented handling method is manual load/pick; gravity moves cartons. The exact equipment envelope must be checked before the aisle or bay layout is approved.

What stock-rotation method does Flow Racks support?

The documented stock-rotation approach is guaranteed fifo (gravity-enforced).

Universal Shrusti FAQ block

Where is Shrusti based?

Shrusti is based in Chennai, Tamil Nadu, India, and has more than four decades of material-handling and storage-system experience.

Does Shrusti design and install racking systems?

Yes. The project scope can cover requirement study, layout, system selection, supply, installation, handover and ongoing support.

Can a racking layout be customised?

Yes. Bay dimensions, levels, row lengths, access routes, storage method and accessories are selected around the confirmed load, inventory profile and facility.

Is AMC and inspection support available?

AMC, preventive maintenance and rack-inspection support can be included in the commercial scope for the installed system.

What should I share for a quotation?

Share the facility layout, clear height, load dimensions and weight, SKU and pallet profile, required storage capacity, handling equipment and target project timeline.

What is Flow Racks, and when should a warehouse use it?

Carton flow racks use slightly inclined lanes of wheels or rollers so cartons and boxes loaded at the replenishment end slide by gravity to the picking end, at the opposite aisle. Warehouses use them for high-volume case or box order picking where reliable stock rotation and fast replenishment matter, since separate aisles keep restocking and picking from interfering with each other and cartons queue in loading order. Common applications include e-commerce and general fulfilment, pharmaceuticals and cosmetics, and automotive or IT parts distribution — and the system can be paired with pick-to-light technology for faster, more accurate picking.

Who should choose Flow Racks?

Choose Flow Racks when the operation has high-volume case/carton order picking and needs lane-front carton only with high storage density.

How is Flow Racks selected?

Selection begins with the load unit, SKU profile, required positions, building envelope and manual load/pick; gravity moves cartons. Final dimensions and ratings follow the approved layout.

Is Flow Racks a fixed online configuration?

No. Flow Racks is a quote-led storage system configured around the facility, load and operating method.

Why choose Shrusti

One accountable path from requirement to operation.

Shrusti has engineered material handling and storage systems from Chennai since 1985. Each racking project starts with the load unit, SKU profile, facility envelope, handling equipment and operating flow, then moves through layout development, structural selection, supply, installation and handover. Customers can also scope site study, commissioning, operator guidance, AMC and lifecycle support through one accountable team.

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Turn the storage requirement into an approved layout and quotation.

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