FIFO Pallet Racking System | First-In First-Out Flow Rack Guide
The FIFO (First-In, First-Out) pallet racking system is a warehouse storage method that ensures the oldest pallet is picked first, making it essential for industries handling dated, perishable or regulated products. FIFO pallet flow racks use gravity driven rollers to move pallets from the loading aisle to the picking aisle, allowing continuous stock rotation without forklifts entering the rack. In this guide, SPS Ideal Solutions explains how FIFO pallet racking works, when it should be used, how it compares to other racking systems and how to select the right FIFO solution for your warehouse.
What Is a FIFO Rack System?
A FIFO pallet racking system is a gravity-based storage system where pallets are loaded from one side and picked from the opposite side. Because pallets move forward automatically, the first pallet stored is always the first one retrieved.
This system is typically built using pallet flow racks that include:
- Roller beds
- Speed controllers
- Braking systems
- Pallet guides
Together, these components ensure safe, smooth, and controlled pallet movement.
How FIFO Pallet Flow Racks Work?
FIFO pallet flow racks operate using sloped roller lanes:
- A forklift loads pallets at the rear (loading aisle)
- Pallets rest on inclined rollers
- Gravity moves pallets forward
- When the front pallet is removed, the next pallet rolls into position
This creates a continuous, automated inventory flow without powered conveyors.
Key Components of FIFO Rack Systems
A professionally designed FIFO system includes:
- Heavy-duty rack frames – support multiple pallet loads
- Gravity rollers – allow pallets to move forward
- Brake rollers – control pallet speed and prevent collisions
- Pallet separators – maintain safe spacing
- Entry & exit guides – align pallets for smooth loading and picking
These elements are engineered based on pallet weight, SKU type and throughput.
FIFO Pallet Racking Specifications
| Feature | Typical Range |
| Pallet weight | 1,000 – 4,500 lbs |
| Pallet depth | 2 to 10+ pallets per lane |
| Rack height | Up to 40 ft |
| Roller type | Steel or polymer |
| Throughput | High-volume, continuous |
Industries That Use FIFO Pallet Racking
FIFO pallet flow racks are essential for:
- Cold storage & food distribution
- Beverage and dairy warehouses
- Pharmaceutical and medical storage
- Chemical and regulated goods
- 3PL and fulfillment centers
These industries require strict inventory rotation, batch tracking and compliance.
FIFO vs Other Pallet Racking Systems
| Feature | FIFO Pallet Flow | Push-Back (LIFO) | Selective Racking |
| Inventory rotation | Excellent | Poor | Manual |
| Aisle usage | Two aisles | One aisle | One aisle |
| Storage density | High | High | Low |
| Perishable goods | Ideal | Not suitable | Limited |
| Throughput | Very high | High | Moderate |
FIFO racks are best when product age, expiration, and traceability matter.
When Should You Use FIFO Racking?
FIFO pallet racking is ideal if:
- Products have expiry dates
- You manage batch or lot numbers
- Inventory moves daily
- You need high-speed picking
- Compliance and audits are required
If stock rotation is critical, FIFO is the most reliable racking system.
Why Warehouses Choose FIFO Pallet Flow Racks?
- Reduces product expiration and waste
- Improves inventory accuracy
- Increases picking speed
- Reduces forklift travel
- Maximizes storage density
This makes FIFO systems a long-term operational investment.
Why Choose SPS Ideal Solutions for FIFO Racking?
SPS Ideal Solutions designs and delivers custom FIFO pallet flow rack systems for warehouses that require precision, compliance, and high-throughput storage. Our team evaluates your SKU profile, pallet loads and picking volume to engineer a system that maximizes both space and operational efficiency.
Frequently Asked Questions About FIFO Pallet Racking Systems
What is a FIFO pallet racking system?
A FIFO pallet racking system is a gravity-based storage system that ensures the first pallet stored is the first one picked, improving stock rotation and inventory control.
What is the difference between FIFO and LIFO racking?
FIFO racks load and pick from opposite sides, while LIFO racks (push-back systems) load and pick from the same aisle, meaning the newest pallet is picked first.
Are FIFO racks suitable for cold storage?
Yes. FIFO pallet flow racks are widely used in cold storage, food, and pharmaceutical warehouses where expiration control is critical.
How much weight can FIFO racks hold?
Most FIFO pallet flow racks support between 1,000 and 4,500 lbs per pallet, depending on the system design.
Can FIFO pallet racks be customized?
Yes. FIFO racks can be engineered for pallet size, weight, lane depth, throughput, and warehouse layout.
Related Posts:
- 7 Important Warehouse Pallet Racking Tips to Maximize Productivity
- Why Do You Need The Pallet Shuttle System In Your Warehouse?
- How to Design your Warehouse Racking Layout for Optimization?
- An Essential Guide: Things to Consider Before Buying Pallet Racks
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