How Well Does Push-Back Flow Rack Handle Different Pallets? | Mallard Manufacturing

If you’re looking for a high-density storage solution for LIFO inventory that accommodates a variety of pallet sizes and styles, push-back flow rack may be your best fit. In this test, our team demonstrates how the full-roller design handles both wood and plastic pallets—smoothly and reliably. The result? A durable, low-maintenance alternative to cart-based systems, offering deeper lanes and greater operational flexibility.

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Discover the latest test results that reveal the performance of LIFO storage with both wood and plastic pallets.

Let' first start with the basics: What Is Push-Back Flow Rack?
Push-back flow rack is a gravity-fed storage solution that uses rollers or wheeled tracks set on a slight pitch. As pallets are loaded, they’re pushed back in the lane; when a pallet is removed, the rear pallets automatically flow forward using gravity. Like traditional cart-based systems, this rack follows a Last-In/First-Out (LIFO) sequence — but that’s where the similarities end.
Mallard’s design eliminates carts altogether, instead relying on high-performance gravity flow rollers and wheels. Without moving carts to maintain, the system is more durable, easier to service, and allows for a shallower pitch — enabling deeper lanes, up to 12 pallets deep, compared to just 5 with cart-style systems.
The full-roller system tested here also provides a significant advantage: it can handle a wider range of pallet types, something that’s not possible with cart-based push-back racks.

Test Setup: Real Pallets, Real Results
The customer supplied two pallet types for our in-house engineering team to test. Here are the flow lane design specs:
System Configuration:
Rollers: 1.9” diameter, set on 3” centers
Lane Pitch: ½” per foot
Flow Type: LIFO (Last-In/First-Out)
Pallet Types:
Wood Pallets (CHEP-style)
40”W x 48”D x 36”H, 2300 lbs loaded
Condition: Well-used, some exposed nails, broken bottom boards, loose wrap

Plastic Waffle-Style Pallets
36”W x 47.5”D x 48”H, 2120 lbs loaded
Condition: Structurally sound, but with dangling stretch wrap

How Did the Rack Perform?
Both pallet styles flowed smoothly through the lane during the loading and unloading process.
Test Results Summary:
Loading: Pallets advanced easily with steady push force
Overnight Rest: No issues after letting pallets sit in-lane overnight
Unloading: Smooth return with no hang-ups for either pallet type
Recommendation: Secure all plastic wrap before loading — loose material can interrupt flow
Corrective Actions (if needed):
Use the plugging method if hang-ups occur
Avoid using pallets with broken boards or protruding nails, as they can damage the flow system and cause pallet hang-ups
Remove or secure dangling plastic wrap that can get caught in the rollers

Best Practices for Push-Back Flow Operation
Proper pallet handling is key to ensuring operator safety, consistent flow, and long system life. To avoid damage and maintain performance, forklift operators should load pallets straight—never at an angle—and use controlled, deliberate movements during both loading and unloading.
Avoid dropping pallets or using excessive force, as this can damage the rack structure and compromise pallet flow. Instead, emphasize slow, steady loading and unloading to keep your system running smoothly.

Loading Guidelines:
Align the pallet squarely at the lane entry
Enter the lane with the pallet raised 2–3 inches above the lane
Gently lower the pallet onto the rollers or wheels
Slowly back out of the lane, allowing the lane’s ramp stop to secure the pallet in place
For additional pallets, push back the front pallet carefully and repeat the process:
Lower the new pallet into position
Back out slowly to allow the stop to catch and hold the pallet

Unloading Guidelines:
Secure the front pallet with the forks, leaving a 4–6 inch gap at the rear to avoid catching the next pallet behind it
Raise the pallet 2–3 inches above the lane
Back out slowly — the operator controls the flow speed of the rear pallets as they advance to the pick face
If the rear pallets do not advance, re-enter the lane briefly to apply a gentle nudge --this is known as the plugging method

Why Choose Mallard Push-Back Flow Rack?
Your storage system should adapt to the way you work — not the other way around. Mallard’s push-back flow lanes offer a more versatile LIFO option than cart systems, especially when managing inconsistent pallet types or product lines.
You get:
Deeper storage capacity
More consistent flow, even with imperfect pallets
Fewer moving parts, less maintenance
Custom testing with your own pallets before installation