--- title: "Flow Through Racking in Waukegan, IL | Free Layout" url: https://chicagopalletracks.com/service-area/waukegan/pallet-flow-rack description: "We design and install pallet flow racking for pharmaceutical & medical operations in Waukegan, IL. Free layout. Call (312) 815-2445." lang: en --- Image: Pallet Flow Rack system inside a Illinois warehouse (https://chicagopalletracks.com/assets/pallet-flow-hero-DopNMGK8.jpg) Waukegan, Illinois # Flow Through Racking in Waukegan, Illinois If your Waukegan operation is dealing with a building between Chicago and Milwaukee trying to serve both markets out of a floor that was sized for one, you are not alone. In Waukegan, a mix of older lakefront industrial buildings and newer distribution space along I-94 serving both Chicago and Milwaukee, and that usually shows up as high-turn SKUs that need a constant pick face. Pallet flow rack loads from one aisle and picks from another on gravity rollers, so the oldest pallet is always the next one out and nobody hand-rotates stock. Before anything is ordered, your Waukegan team gets a drawing, a position count, and a line-item price, so the decision is based on numbers. Call (312) 815-2445 to start a free layout. (312) 815-2445 ## Why Waukegan Warehouses Work With Us Warehouses near the Grand Avenue industrial corridor and the lakefront harbor district each come with their own limits: usable height, column spacing, dock count. In Waukegan, a mix of older lakefront industrial buildings and newer distribution space along I-94 serving both Chicago and Milwaukee, so we draw every pallet flow rack layout to the actual building. As a division of Warehouse Equipment & Supplies Co., we have designed storage for pharmaceutical & medical and manufacturing operators across Chicagoland since 1997. For pallet flow rack, the fit question is usually gravity lanes loaded on one side and picked on the other, and we answer it during a free warehouse consultation before you commit. Steel moves from our Westmont warehouse to Waukegan in about an hour over I-94, Route 41, and Route 120. 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: Pallet flow rack lanes with gravity rollers installed (https://chicagopalletracks.com/assets/pallet-flow-rack-2-IPjxgmn1.jpg) Image: Flow racking system loaded with pallets at the pick face (https://chicagopalletracks.com/assets/pallet-flow-hero-DopNMGK8.jpg) ### Operations We Rack Around Here Nearby areas we work in regularly include the Waukegan National Airport area, the Grand Avenue industrial corridor, the Route 41 and I-94 corridor, the lakefront harbor district. Pharmaceutical & medical Manufacturing Distribution Food & beverage ## How Pallet Flow Rack Works Load one side, pick the other, and let gravity enforce first in, first out. 1 ### Load end Pallets enter at the high end of the lane. Each new pallet stages behind the one before it, so put-away is a single move made from the load-side aisle. 2 ### Gravity conveyor Full-width rollers or skate-wheel tracks, set on a pitch calculated for the pallet weight, carry loads forward under control rather than free rolling. 3 ### Braking and separation Brake rollers and pallet separators regulate travel and stop pallets from bunching, protecting both the product and the structure underneath it. 4 ### Pick end Pickers work a face of first-in pallets. Pull one and the next indexes forward automatically, so the pick aisle stays organized without anyone re-facing stock. ## What a Pallet Flow Rack Project Includes Every pallet flow rack project in Waukegan begins with the numbers: what you store, how heavy it is, what lifts it, and how tall the usable space is. We collect those during a free warehouse consultation by phone, along with a floor plan or a few photos if you have them. The deliverable is a CAD layout and a priced bill of material: positions, elevations, aisle widths, and capacities. Since five to twenty pallets deep behind a single pick face drives the design, we often model the same Waukegan 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 Waukegan 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. Date-coded food, beverage, and pharmaceutical inventory High-volume SKUs with steady, predictable turns Cold storage where every cubic foot carries a cost Staging finished goods coming off a production line Operations that need FIFO documented, not just assumed 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 Pallet Flow Rack Quote for Your Waukegan 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 ## Pallet Flow Rack Questions We Hear Most ### How quickly can pallet flow rack be delivered and installed in Waukegan? ### Does pallet flow rack work in Waukegan buildings near Waukegan National Airport area? ### Which Waukegan operations get the most out of pallet flow rack? ### How deep should our flow lanes run? ### Our pallet pool is rough. Will that jam the lanes? ### How is pallet flow laid out in a freezer building? ### How much aisle space do our forklifts need at each end? ## Other Rack Types & Services in Waukegan ### Pallet Rack Every pallet reachable, every time. The baseline we size everything else against. View details https://chicagopalletracks.com/service-area/waukegan ### Pushback Rack Two to six pallets deep from one aisle, without giving up much reach. View details https://chicagopalletracks.com/service-area/waukegan/pushback-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/waukegan/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/waukegan/cantilever-rack ### Carton Flow Rack Cases advance to the picker instead of the picker hunting for cases. View details https://chicagopalletracks.com/service-area/waukegan/carton-flow-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/waukegan/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. Pallet Flow Rack in Chicago: https://chicagopalletracks.com/service-area/chicago/pallet-flow-rack Pallet Flow Rack in Aurora: https://chicagopalletracks.com/service-area/aurora/pallet-flow-rack Pallet Flow Rack in Naperville: https://chicagopalletracks.com/service-area/naperville/pallet-flow-rack Pallet Flow Rack in Joliet: https://chicagopalletracks.com/service-area/joliet/pallet-flow-rack Pallet Flow Rack in Elgin: https://chicagopalletracks.com/service-area/elgin/pallet-flow-rack Pallet Flow Rack in Cicero: https://chicagopalletracks.com/service-area/cicero/pallet-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 Pallet Flow Rack in Waukegan? Call (312) 815-2445 or request a quote and we will get a layout started. 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In Waukegan, a mix of older lakefront industrial buildings and newer distribution space along I-94 serving both Chicago and Milwaukee. We plan the pallet flow rack around your column grid, clear height, and dock layout so pallet positions land where the building allows, and we show you the position count before you order." } }, { "@type": "Question", "name": "Which Waukegan operations get the most out of pallet flow rack?", "acceptedAnswer": { "@type": "Answer", "text": "We see it pay off most for pharmaceutical & medical and manufacturing operations in Waukegan, especially where high-turn SKUs that need a constant pick face is the daily headache. During a free warehouse consultation we compare pallet flow rack with other options for your SKUs so you can see whether it is the right fit." } }, { "@type": "Question", "name": "How deep should our flow lanes run?", "acceptedAnswer": { "@type": "Answer", "text": "Five to twenty pallets is typical. Depth should match how much of one SKU moves through in a cycle - a lane that never fills is wasting a pick face. We size depth from your actual movement data, not a rule of thumb." } }, { "@type": "Question", "name": "Our pallet pool is rough. Will that jam the lanes?", "acceptedAnswer": { "@type": "Answer", "text": "Broken bottom boards and heavy overhang cause most hang-ups in flow lanes. If your pallets vary, full-width rollers are the safer specification, and we say so up front rather than after installation." } }, { "@type": "Question", "name": "How is pallet flow laid out in a freezer building?", "acceptedAnswer": { "@type": "Answer", "text": "Cold changes the layout, not just the hardware. Freezer buildings here concentrate storage to shrink the refrigerated envelope, so lanes often run deeper than they would in ambient space. Components are specified for the temperature so bearings and brakes behave in the cold." } }, { "@type": "Question", "name": "How much aisle space do our forklifts need at each end?", "acceptedAnswer": { "@type": "Answer", "text": "The load aisle and pick aisle each need enough room for the trucks using them, including the pallet's length and turning space. We check your forklift dimensions and loaded reach before fixing lane depth. In older Bedford Park buildings, a shallower lane may leave the working room your drivers need without sacrificing access to the pick face." } } ] } ] ```