Carton Live Storage

The dynamic picking system, also known as AR Carton Flow, is a gravity-fed storage solution for boxes, trays, and light goods. Products are loaded at the rear from the replenishment aisle and travel automatically along inclined roller or wheel tracks to the picking face, where they are available for order preparation.

It is a FIFO system especially useful for high-turnover SKUs, enabling replenishment from the rear aisle to take place simultaneously with picking from the front, eliminating interference between replenishment and picking teams and improving the continuity of operational flow.

It improves productivity by separating replenishment and order preparation tasks: replenishment takes place from one aisle whilst picking is carried out from the other, reducing interference between operators and equipment. Gravity moves the product forward to the picking face, ensuring that stock is always available in the preparation zone.

This is particularly valuable for SKUs that are exhausted during a single picking wave, since replenishment can continue without interrupting picking. This reduces travel, avoids stoppages, and increases output per order line.

Dynamic picking shelving is designed for boxes, trays, containers, and small or lightweight products that have a stable base and can travel along the roller or wheel tracks without tipping or jamming. Cardboard boxes, plastic containers, and standardised trays are the most common choices.

Goods with irregular shapes, very low weight, or unstable bases may not be suitable for gravity flow and should be assessed individually during the project design phase.

Straight frames are used primarily when complete boxes are extracted or when a specific product presentation at the picking face is not required. They provide a simple, cost-effective channel structure for standard box sizes.

Presentation trays are used when the product needs to be displayed or positioned in a specific orientation at the picking face — for ergonomic picking, visual stock checks, or improved pick accuracy.

Yes. Dynamic picking shelving can be combined with conventional pallet racking, integrating picking levels within the same structure as the pallet storage positions. This is a common configuration in split-level warehouse designs, where pallet reserves are held in the upper levels and dynamic picking positions occupy the lower levels of the same bay.

This combined approach optimises the use of available height and simplifies replenishment logistics.

The system is compatible with cardboard boxes, plastic boxes, trays, and containers with a stable flat base, provided that the dimensions and weight fall within the design parameters of the channel. Channel width, track pitch, and track spacing are selected during the design phase to suit the specific box format.

Mixed box formats can be accommodated within the same installation by configuring different channel widths and track spacings for different product zones.

AR Racking’s dynamic picking shelving systems are designed and calculated in accordance with the applicable standards and with consistent quality controls throughout the manufacturing process. All installations include the safety accessories required by the applicable standards, including shelf locking clips, front stops, and lateral guides to prevent boxes from falling from the picking face.

Yes. Carton Flow shelving is a suitable solution for operations based on Lean Manufacturing and Kanban methodologies. The FIFO flow ensures that the oldest stock is always presented at the picking face, supporting pull-based replenishment systems where replenishment is triggered by the consumption of the last box in the channel.

This makes it straightforward to implement visual Kanban signals at the channel entry point, ensuring timely replenishment and avoiding both stockouts and overstocking.

Yes. Dynamic picking shelving is designed specifically to operate under FIFO principles, ensuring that the first box or unit to enter the channel is also the first to be picked. This is inherent to the gravity-flow design: new stock is always loaded at the rear, and the oldest stock is always presented at the front.

This makes the system particularly suitable for products with an expiry date, a batch traceability requirement, or any operation where stock rotation is a quality or regulatory requirement.

Yes. Dynamic picking shelving can be integrated with warehouse management systems and picking support technologies such as Pick to Light, voice picking, or RF scanning. Pick to Light systems can be mounted at the channel face, guiding operators to the correct location and confirming the quantity to be picked.

Integration requirements should be defined during the project design phase to ensure that mounting points, cable management, and data connectivity are incorporated into the shelving structure from the outset.

Dynamic picking shelving does not require the specialist maintenance of an automated machine. Routine maintenance should follow the same principles as for any industrial shelving system: periodic visual inspections to check the condition of the tracks, rollers, and structural components; prompt replacement of any damaged or worn elements; and verification that the load notice specifications are not being exceeded.