Carton live storage uses inclined roller or wheel tracks to move cartons automatically from the loading end to the picking face under gravity. Stock is loaded from the back and picked from the front, creating automatic FIFO rotation without any manual stock movement.
It’s built for high-volume, fast-moving carton picking, particularly where FIFO rotation is required. Absolute Storage Systems designs and installs carton live storage systems across Australia, configured to your carton sizes, weights and pick rates.
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Carton live storage consists of inclined tracks fitted with rollers or wheels, mounted within a shelving or racking structure. Cartons are loaded at the rear of the lane and travel forward automatically as items are picked from the front. Each lane can hold a different SKU, and the system accommodates multiple shelf levels.
It suits operations with high pick rates and a need for consistent FIFO rotation, such as food and beverage distribution, pharmaceuticals, or e-commerce fulfilment. The key design consideration is matching the track incline and roller/wheel type to your specific carton weight and base material, since these affect how reliably cartons travel forward and stop at the picking face.
Carton live storage only works reliably when the track system is correctly specified for the carton being stored. Track incline, roller spacing and lane depth all need to be matched to your actual carton dimensions and weights. Absolute Storage Systems has been designing and installing live storage systems since 1991.
We assess your carton sizes, weights, pick rates and FIFO requirements to confirm carton live storage is the right fit.
We design lane depth, track incline and roller configuration around your specific carton and pick profile.
Professionally installed and tested to confirm reliable carton flow before handover.
We verify track incline, carton travel and lane stopping performance before the system goes live.
We provide maintenance and reconfiguration as your carton profile or pick requirements change.
Manual FIFO rotation is slow, error-prone and relies on staff discipline. Carton live storage automates the process entirely, keeping the right stock at the picking face at all times without additional handling.
If you’re running high-volume carton picking and FIFO rotation matters, carton live storage is worth exploring. Our team can assess your carton profile and pick rate, contact us to get started.
Carton live storage is a picking system where cartons sit on gently inclined roller or wheel tracks within a shelf or rack frame. Cartons are replenished from the rear and roll forward to a pick face at the front as stock is taken. Because replenishment and picking happen on opposite sides, stock rotates first in, first out and pickers never wait on a restock.
They work the same way and are built for different unit sizes. Pallet live storage moves full pallets on heavy duty roller tracks and is loaded by forklift. Carton live storage moves individual cartons, trays or bins on light wheel beds, and is picked by hand at a pick face. The two are often combined, with carton flow at pick height and pallet storage above it.
It reduces walking. A run of carton flow presents many product lines across a single pick face at working height, so a picker can complete more lines from one position instead of travelling the aisle. Stock also presents itself, so there is no reaching into a shelf or restocking the pick face mid pick
In most cases yes. Carton flow beds are commonly fitted into the lower levels of existing pallet racking to create a pick face, with full pallet storage kept above as replenishment stock. Whether your current frames suit it depends on beam spacing, frame depth and the load rating of the existing system, which we check on site. Our CLS have special brackets that make it universal across the major racking brands
Small to mid-sized cartons work best due to the nature of the slopping decline of the beds of rollers. This isn’t a system that is suited to heavy cartons.
As per the Australian Standard (AS4084:2023), pallet racking audits are now mandatory and must be completed every 12 months.
Ensure your facility is safe and fully compliant with a free onsite audit from our expert team.
