3 Use Cases for Modular Flow Racks from FlexMation

Manufacturing and assembly operations are under constant pressure to do more with fewer resources. Fluctuating demand, tight labor markets, and the need for faster throughput all push facilities to remove waste and improve material flow. One of the most effective ways to support these goals is to make sure parts move efficiently, reliably, and ergonomically from storage to point of use.

FlexMation designs and builds custom modular flow racks that do exactly that. Our engineers create solutions that match your footprint, your parts, and your process, instead of forcing your teams to work around a one-size-fits-all rack. We frequently integrate components from trusted partners such as UNEX when they are the best fit, but every system is designed around your exact application.

What Are Flow Racks?

Flow racks, sometimes called gravity racks or supermarket racks, use slightly inclined lanes with rollers or wheel beds so that containers, boxes, or totes move forward as items are picked. New product is

loaded from the back, older product flows to the front, and operators always pick from the first in line. This supports first-in, first-out (FIFO) inventory control, reduces walk time, and keeps pick faces organized and easy to access.

FlexMation designs flow racks using modular aluminum extrusion, custom roller lanes, work surfaces, casters, and accessories, so they can be adapted for everything from light plastic totes to heavy metal components.

Well-designed gravity flow racks help businesses:

• Improve pick rates and reduce search time for parts
• Support FIFO inventory rotation and better stock control
• Cut travel distance and wasted motion for operators
• Keep work areas clean, organized, and safer
• Adapt quickly when product mix or volume changes

Because FlexMation racks are modular and engineered to order, they can be reconfigured as your process evolves instead of becoming obsolete when a product line changes.

Why Custom Matters:

Most facilities start with off the shelf racking. But when part sizes, workflow, or ergonomics change, those fixed racks no longer support efficient production. FlexMation designs each system around your exact bins, totes, load requirements, and operator reach, so the rack fits the process, not the other way around.

Real-World Examples of Custom Flow Rack Designs

Below are a few examples of custom flow rack concepts created by FlexMation for different types of facilities. Each design started with the customer’s parts, process, and goals, then our team modeled and built the optimal solution

Workstation racks

• Tilted workstation

Compact tilted workstation rack that presents parts at an ergonomic angle for operators. (Designed and built by FlexMation.)

• Hybrid workstation + flow rack

Hybrid rack that combines gravity flow lanes with a top work surface for assembly or inspection. (Designed and built by FlexMation.)

Storage and supermarket racks

• Multi lane flow rack

Example of a compact multi-tier gravity flow rack designed and built by FlexMation.

• Long angled rack

Large angled flow rack for long or heavy components requiring steeper pitch and robust support. (Designed and built by FlexMation.)

• Fixed shelf rack

Fixed shelf rack for staging heavy or static parts near the point of use. (Designed and built by FlexMation.)

Mobile racks

• Mobile cart with shelves

Mobile flat shelf cart: ideal for mixed component transport, staging, and replenishment. (Designed and built by FlexMation.)

Workstation Part Presentation and Kitting

Assembly and kitting stations are often the heart of a production line. When parts are hard to reach or constantly running out, throughput suffers. Custom flow racks from FlexMation can be designed to sit directly at the workstation, with each lane sized to your bins, trays, or totes.

Common features include:

• Adjustable lane width, pitch, and number of levels
• Integrated work surfaces for assembly, inspection, or packaging
• Label holders, part dividers, and tool mounts
• Tilting shelves that bring parts into the operator’s natural reach zone

The result is faster picking, less bending and reaching, and more consistent output from every operator on the line.

Line-Side Supermarkets and Kanban Replenishment

Many facilities use supermarket areas to stage parts close to production while freeing up space at the primary workstation. Custom gravity racks are ideal for these line-side supermarkets. FlexMation can configure racks with multiple levels and clearly defined lanes so that material handlers can quickly see what needs replenishment and operators always have what they need.

Benefits include:

• FIFO flow that protects date-sensitive or revision-sensitive components
• Visual management that makes low stock immediately obvious
• Improved handoff between warehouse, supermarket, and production
• The ability to support kanban or other pull-based material systems

When paired with modular conveyor, carts, or other handling equipment from FlexMation, supermarket racks become part of a complete material flow system rather than a stand-alone fixture.

Mobile Carts and Changeover Support

Not every process is tied to a fixed location. Mobile flow racks and cart-style racks make it easy to move parts between cells, support quick changeovers, or temporarily stage components near maintenance or rework areas.

FlexMation designs mobile racks with:

• Heavy-duty casters and brakes for safe movement and stable use
• Hybrid configurations that mix flat shelves with flow lanes or tilt trays
• Handles and bumpers that protect both the cart and surrounding equipment
• Frames sized to fit your aisles, docks, and doorways

These mobile systems help reduce forklift traffic, shorten travel distance, and keep operators focused on value-added work instead of hunting for parts.

Why Work with FlexMation for Custom Flow Racks

Off the shelf racks can be a good starting point, but they rarely match your process perfectly. FlexMation takes a different approach. Our team:

• Reviews your parts, packaging, and material handling methods
• Identifies waste in your current storage and presentation setup
• Models concepts in 3D so you can see how racks will work in your space
• Builds, delivers, and supports turnkey solutions designed for long term use

We can design brand new systems or improve existing lines by reconfiguring racks you already own. When appropriate, we integrate components from suppliers such as UNEX to combine proven hardware with FlexMation’s custom engineering.

To learn more about FlexMation’s modular flow rack options, visit our Flow Racks page. If you would like to discuss a specific application or start a new project, contact us today and our team will help you design the right solution for your facility.