--- title: "Carton Flow Systems in Chicago, IL | Layout & Install" url: https://chicagopalletracks.com/service-area/chicago/carton-flow-rack description: "We design and install carton flow shelving for food & beverage distribution operations in Chicago, IL. Free layout. Call (312) 815-2445." lang: en --- Image: Carton Flow Rack system inside a Illinois warehouse (https://chicagopalletracks.com/assets/carton-flow-hero-y0vnsglk.jpg) Chicago, Illinois # Carton Flow Systems in Chicago, Illinois Freight stacked in the aisles of an older brick building because the floor was never laid out for modern pallet loads is one of the most common problems we see in Chicago right now. Look closer and the real issue tends to be restockers and pickers sharing the same aisle. Carton flow rack feeds cases down sloped wheel beds to a pick face, restocked from the back, so pickers stop waiting on replenishment and stop walking past empty slots. We size the carton flow rack to your loads, your forklifts, and the clear height you already lease, then send a CAD layout with pick faces counted and an itemized quote. Call (312) 815-2445 and tell us what you store in Chicago. (312) 815-2445 ## Why Chicago Warehouses Work With Us Chicago is a market where older multi-story brick buildings with tight column grids and freight elevators sit a few miles from newer single-story boxes with 32-foot clear heights. Whether your building sits near the Stevenson corridor or closer to Midway Airport, the column grid and usable height decide the carton flow rack design, not a catalog drawing. Our team has quoted and installed racking for food & beverage distribution and third-party logistics work in Chicago for decades. With carton flow rack, the deciding factor is normally gravity wheel beds feeding cases to a fixed pick face, and we put the numbers for that in front of you up front. Steel moves from our Westmont warehouse to Chicago in about 35 minutes over I-55, I-90/94, and I-290. Our own installation crews build the system, and the same person who drew your layout answers the phone when a beam gets hit two years later. Free warehouse consultation CAD layout with position counts Installation by our own crews Image: Carton flow rack with gravity wheel beds and case lanes (https://chicagopalletracks.com/assets/carton-flow-rack-DfuFYV4P.jpg) Image: Carton flow shelving in use on a warehouse pick line (https://chicagopalletracks.com/assets/carton-flow-hero-y0vnsglk.jpg) ### Operations We Rack Around Here Nearby areas we work in regularly include the Kinzie Industrial Corridor, Pilsen and the Lower West Side, the Stevenson corridor, the Clearing district near Midway. Food & beverage distribution Third-party logistics E-commerce fulfillment Printing & packaging ## How Carton Flow Rack Works Cases advance to the picker instead of the picker hunting for cases. 1 ### Inclined wheel beds A full-width wheel bed or roller track sits on a slight incline inside a standard bay, so cases move forward under their own weight without power. 2 ### Pick from a fixed position The picker always reaches for the same forward spot in the lane. Travel time drops, and so does the time spent searching for the next case. 3 ### Restock from behind Replenishment loads the high end of the lane from a separate aisle, so restocking never blocks or slows the pick line, and rotation stays first in, first out automatically. 4 ### One lane per SKU Lane dividers set the width for each case size, giving every SKU its own face - a width that can be resized as your product mix shifts. ## What a Carton Flow Rack Project Includes A Chicago carton flow rack project starts with a phone call or a few photos, not a sales pitch. We go through load size and weight, forklift type and lift height, usable clear height in the storage area, column spacing, and how fast product turns. That free warehouse needs analysis usually takes about fifteen minutes. The deliverable is a CAD layout and a priced bill of material: positions, elevations, aisle widths, and capacities. Since fastest-moving SKUs placed at the golden pick zone drives the design, we often model the same Chicago footprint two ways so you can weigh density against picking speed with real figures. Standard components ship from stock, often inside 48 hours, and delivery is timed to your Chicago receiving hours. Our own crews anchor, plumb, and level every frame, tag capacities, and phase the work by zone so shipping keeps moving. Afterward you keep one local number for parts, added levels, reconfigurations, or a future relocation. Case and each picking operations Order fulfillment lines carrying many active SKUs Grocery, beverage, and consumer goods distribution Kitting and light assembly feed lines Bays that need reserve pallets stacked above the pick face Call (312) 815-2445: (312) 815-2445 ## Recent Installations Racking projects completed for warehouses across Chicago and the surrounding suburbs. Image: Carton flow rack installation in a warehouse (https://chicagopalletracks.com/assets/carton-flow-racking-CbC_ZAQs.jpg) Image: Drive-in pallet rack installation in a high-bay warehouse (https://chicagopalletracks.com/assets/drive-in-CzCRNL_F.jpg) Image: Pallet rack installation reaching the ceiling of a distribution center (https://chicagopalletracks.com/assets/igt-6-DlAaWmSY.jpg) Image: Selective pallet rack aisle with wire decking (https://chicagopalletracks.com/assets/img-1220-DJL8pNok.jpg) Image: Warehouse pallet racking aisles with a forklift (https://chicagopalletracks.com/assets/img-5455-DxNygyEY.jpg) Image: Rows of pallet racking in a distribution facility (https://chicagopalletracks.com/assets/medco-cleveland-5-Bg7bEehR.jpg) Image: Warehouse pallet rack system spanning a large storage area (https://chicagopalletracks.com/assets/photo-aug-03-6-17-41-pm-Cpzt32J0.jpg) Image: Pallet racking rows under warehouse skylights (https://chicagopalletracks.com/assets/photo-jul-22-6-45-56-pm-CIVCQxM9.jpg) Image: Cantilever rack arms mounted along a warehouse wall (https://chicagopalletracks.com/assets/photo-may-15-2026-7-28-50-pm-1-zev4C15x.jpg) Image: Push back pallet rack carts on inclined rails (https://chicagopalletracks.com/assets/udf-pushback-rack-BgIv7FXJ.jpg) View More Projects: https://chicagopalletracks.com/projects ## Get a Carton Flow Rack Quote for Your Chicago Warehouse Send the basics and we will follow up with a layout and pricing. Prefer to talk it through? Call (312) 815-2445. ### Chicago Pallet Racks 36 N. Cass Ave. Unit #5170 Westmont, IL 60559 (312) 815-2445 Monday - Friday: 8:00 AM - 6:00 PM ## Carton Flow Rack Questions We Hear Most ### How quickly can carton flow rack be delivered and installed in Chicago? ### Does carton flow rack work in Chicago buildings near Kinzie Industrial Corridor? ### Which Chicago operations get the most out of carton flow rack? ### What is carton flow rack actually used for? ### Do soft or lightweight cartons flow well? ### Can carton flow drop into racking we already own? ### How many lanes should each SKU get? ## Other Rack Types & Services in Chicago ### Pallet Rack Every pallet reachable, every time. The baseline we size everything else against. View details https://chicagopalletracks.com/service-area/chicago ### Pushback Rack Two to six pallets deep from one aisle, without giving up much reach. View details https://chicagopalletracks.com/service-area/chicago/pushback-rack ### Pallet Flow Rack Load one side, pick the other, and let gravity enforce first in, first out. View details https://chicagopalletracks.com/service-area/chicago/pallet-flow-rack ### Drive-In Rack No aisles. The forklift enters the structure, and the floor holds more pallets per square foot than any other system. View details https://chicagopalletracks.com/service-area/chicago/drive-in-rack ### Cantilever Rack Arms with nothing in front of them, built for lumber, pipe, and anything a pallet can't hold. View details https://chicagopalletracks.com/service-area/chicago/cantilever-rack ### Warehouse Relocation We tear down, move, and reinstall your pallet rack so the new building is ready to receive on day one. View details https://chicagopalletracks.com/service-area/chicago/warehouse-relocation ## Nearby Areas We Also Serve Our delivery and installation territory covers Chicago and the surrounding suburbs, so one team can handle multiple buildings for the same company. Carton Flow Rack in Aurora: https://chicagopalletracks.com/service-area/aurora/carton-flow-rack Carton Flow Rack in Naperville: https://chicagopalletracks.com/service-area/naperville/carton-flow-rack Carton Flow Rack in Joliet: https://chicagopalletracks.com/service-area/joliet/carton-flow-rack Carton Flow Rack in Elgin: https://chicagopalletracks.com/service-area/elgin/carton-flow-rack Carton Flow Rack in Waukegan: https://chicagopalletracks.com/service-area/waukegan/carton-flow-rack Carton Flow Rack in Cicero: https://chicagopalletracks.com/service-area/cicero/carton-flow-rack View All Service Areas: https://chicagopalletracks.com/service-area ## Where We Work Located in Chicago, we serve the entire Chicagoland area with industrial pallet racks and warehouse storage solutions. ### Chicago Pallet Racks #### Address 36 N. Cass Ave. Unit #5170 Westmont, IL 60559 #### Phone (312) 815-2445 #### Business Hours Monday - Friday: 8:00 AM - 6:00 PM Saturday: Closed Sunday: Closed ## Need Carton Flow Rack in Chicago? Call (312) 815-2445 or request a quote and we will get a layout started. 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In Chicago, older multi-story brick buildings with tight column grids and freight elevators sit a few miles from newer single-story boxes with 32-foot clear heights. We plan the carton flow rack around your column grid, clear height, and dock layout so pick faces land where the building allows, and we show you the position count before you order." } }, { "@type": "Question", "name": "Which Chicago operations get the most out of carton flow rack?", "acceptedAnswer": { "@type": "Answer", "text": "We see it pay off most for food & beverage distribution and third-party logistics operations in Chicago, especially where restockers and pickers sharing the same aisle is the daily headache. During a free warehouse consultation we compare carton flow rack with other options for your SKUs so you can see whether it is the right fit." } }, { "@type": "Question", "name": "What is carton flow rack actually used for?", "acceptedAnswer": { "@type": "Answer", "text": "Case and piece picking. Cartons ride gravity wheel beds so the next unit advances to the pick face automatically, cutting walking time and keeping the line organized as SKU counts climb." } }, { "@type": "Question", "name": "Do soft or lightweight cartons flow well?", "acceptedAnswer": { "@type": "Answer", "text": "Full-width wheel beds handle mixed and flimsy cartons far better than spaced roller tracks. If your cases vary in stiffness, that's the specification we'll recommend, and we test travel with your actual cartons at installation." } }, { "@type": "Question", "name": "Can carton flow drop into racking we already own?", "acceptedAnswer": { "@type": "Answer", "text": "Frequently. Wheel beds and track can go into existing bays when frame depth and beam spacing allow it. We verify your current profile first and convert only the bays that fit." } }, { "@type": "Question", "name": "How many lanes should each SKU get?", "acceptedAnswer": { "@type": "Answer", "text": "Fast movers often earn two or more lanes so the face doesn't run dry between replenishments, while slow movers can share a level. We assign lanes from pick data, not by splitting the bay evenly." } } ] } ] ```