In today's fast-moving distribution hubs, warehouse managers face constant pressure to improve picking speeds while saving floor space. A Carton Flow Storage System is one of the most effective tools for meeting these demands. Unlike static shelves that require pickers to walk deep into aisles, carton flow systems work on a gravity-fed, First-In, First-Out (FIFO) process. Pallets or boxes are loaded from the rear loading aisle and slide smoothly on inclined roller tracks down to the front picking face.
This continuous replenishment loop separates stocking activities from picking processes. The result is a major increase in efficiency. Picking paths are shortened, restocking errors are minimized, and product rotation is handled automatically by gravity. For high-volume operations handling diverse SKUs, carton flow racks are the backbone of smart order fulfillment.
Ensures that older inventory is picked first, making it ideal for date-sensitive items, pharmaceuticals, cosmetics, and food & beverage storage.
By grouping picking faces closer together, you can reduce travel time for staff by up to 50% compared to traditional static shelving units.
Saves up to 30% of warehouse floor space by eliminating unnecessary transit aisles and using the full height of your storage racks.
Established in 2015, Shenzhen Sunli Intelligent Logistics Equipment Co., Ltd. has grown into a leading manufacturer of heavy-duty industrial racking and smart warehouse storage systems. Operating from a modern production facility spanning 38,000 m², we use our 12+ years of industry experience and 8 years of international trade expertise to support global logistics and industrial operations.
Our high-performance storage systems generate between $18 million and $25 million in annual export revenue, serving key markets in North America, Western Europe, Southeast Asia, and the Middle East. With strong R&D resources, including 28 skilled engineers, we continuously adapt to new supply chain needs by introducing over 120 new designs and structural improvements every year.
We manage every step of production in-house. From raw material inspection to automated roll forming, robot welding, and powder coating, our process ensures structural stability and long-term durability.
Building a reliable carton flow system requires precise engineering. Standard designs often suffer from common issues, such as boxes getting stuck or packages moving too fast and colliding at the picking face. At Sunli, our engineers calculate the optimal decline slope based on the exact weight, size, and material of your packaging:
Our manufacturing process uses high-yield structural steel (Q235B or Q355B), ensuring that frames support high-density configurations without bowing under pressure. We also provide customized ESD (Electrostatic Discharge) protection. This grounding safeguard is essential for warehouses handling sensitive electronics, automotive computers, or semiconductor components.
Sourcing industrial racking systems from China provides access to a highly efficient and well-integrated supply chain. Operating out of Shenzhen, Sunli is located in the center of one of the world's most advanced logistics and manufacturing clusters. Our network of over 800 supply chain partners allows us to source raw materials, custom components, and specialized surface coatings quickly and cost-effectively.
This local ecosystem helps us keep delivery times short, even for highly customized orders. While maintaining competitive pricing, we focus on rigorous quality standards. We perform structural safety assessments using finite element analysis (FEA) to confirm our racks meet international standards, including the European FEM 10.2.02 and US RMI guidelines.
Our team of 35 Quality Control professionals uses dedicated laboratory equipment to verify the durability, coating adhesion, and load capacity of every production run.
Installing a storage system requires meeting local structural and safety rules. In seismic zones, such as parts of the US west coast or Japan, racks must be designed to withstand movement. Sunli engineering incorporates seismic calculations directly into our AutoCAD layouts and structural modeling, selecting the appropriate baseplates, anchor bolts, and bracing patterns for each site.
We also support our customers long after the sale. From clear installation guides and 3D step-by-step videos to partnering with local assembly crews, we work to ensure your installation is efficient and safe. Every component is labeled and packed carefully to prevent damage during shipping, so your materials arrive ready for quick, on-site assembly.
The optimal slope typically falls between 2.5% and 4.5%. This angle depends on the weight of the cartons, the wheel material, and the stiffness of the box. Lightweight cardboard boxes require a slightly steeper slope (approx. 4%) to keep moving, while heavier plastic bins glide easily at a lower angle (approx. 3%). We run structural simulations and physical tests to establish the correct slope for your inventory.
We use high-density polyethylene (HDPE) or polypropylene (PP) wheels for standard, low-noise warehousing. For heavy loads or high-temperature settings, we offer steel rollers with precision bearings. In cold storage environments, we use sub-zero rated plastic components that stay resilient and avoid cracking in temperatures down to -30°C.
Yes. Our carton flow frames are designed to easily fit digital accessories, such as pick-to-light bars, barcode scanners, and entry sensors. This compatibility makes it straightforward to integrate our racks into warehouse management systems (WMS) and automated layouts.
Depending on custom configurations and order size, production typically takes 20 to 35 days from layout approval to container loading. Our local network of 800 supply chain partners helps us keep raw material lead times short, ensuring reliable delivery schedules.
SunliRack