Carton Flow Rack Systems

Carton Flow Racks From Converted Pallet Racks

DuraFlow DF2 is a carton live storage product that converts most brands of pallet racks and long-span shelving systems into carton flow racks, whether double- or single-sided bays, using either our heavy duty GP40 or standard duty GP35 roller tracks and suitable adaptor components and profiles.

FIFO (first in, first out) stock is automatically presented ‘ready to pick’, resulting in shorter picking routes and faster pick rates.

DuraFlow DF2 replaces both our original DuraFlow product (manufactured in the UK from 2006) and LS2 (now discontinued).  The new design has considerable advantages.    

It has a denser pattern of wheels for improved rolling characteristics, no lane reconfiguring is required for changing carton/container sizes, and it offers lane divider guide options not previously achievable.


Versatile Carton Live Storage

DuraFlow DF2 provides a densely packed bed of rollers for ultimate flexibility; different box sizes can be accommodated across the entire bed without the need to set up guides or re-position individual roller tracks.

Standard DF2 GP40 series wheel density is approximately 345 wheels per square metre, with each DF2 shelf level typically having roller tracks at 80mm centres across the bay width.

The track centres can be varied for special live storage requirements, further increasing wheel density for smaller packages.

DF2 - flowrack

Strong Roller Tracks

DuraFLow DF2 is designed to give years of trouble-free service, and roller track sections have sturdy steel axles with reinforced polypropylene rollers. The rollers are fitted to pre-galvanised steel profiles for strength and rigidity.

Simple Flow Racks

DF2 roller track sections are supplied ready for immediate installation without tools.

Quick Live Storage

Quick Live Storage

It is quick to install, just a few minutes per shelf level, and no tools required. With rack beams correctly installed for the desired gradient, you position a pair of beam adaptors (on-load and off-load types) on the beams. Then the track sections are simply slotted into place. At the on-load end, roller track wheels will be flush with top of the beam. At the off-load end, the top of roller is 25mm below the beam top face to create an end-stop.

DuraFlow DF2 Beam Adaptor Profiles

DuraFlow DF2 Beam Adaptor Profiles

These profiles are manufactured from galvanised steel sheet to exactly fit the beam dimensions of your chosen rack type. The DuraFlow DF2 roller track sections then sit securely in recesses on an internal ledge formed into the adaptor.

Adaptors provide a continuous smooth outer face to the beam for location labelling.  The adaptors may be re-fitted onto any other beam of identical dimensions.

Generally only two beams are needed for each storage level for depths up to 2.5m, though with heavier loads your carton flow rack may also require a centre support.  The beams should ideally be rectangular in cross section, but adaptors can be made for certain other beam shapes, subject to detailed enquiry.

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