Pallet live storage uses inclined roller tracks to move pallets automatically from the loading end to the picking face under gravity. Pallets are loaded from the rear by forklift and travel forward to the front aisle where they’re retrieved, creating automatic First-In, First-Out rotation without any manual stock movement.
It’s built for high-density storage of products that require strict FIFO rotation, particularly food, beverage, pharmaceutical and cold storage operations. Absolute Storage Systems designs and installs pallet live storage systems across Australia, configured to your pallet weights, dimensions and pick rates.
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Pallet live storage consists of inclined roller tracks mounted within a racking structure. Pallets are loaded at the rear of each lane by forklift and travel forward under gravity to the picking face at the front aisle. As each front pallet is retrieved, the pallets behind it roll forward automatically.
Loading and picking happen at opposite ends of the system, so the two forklift operations don’t interfere with each other. Each lane holds a single SKU and the system can accommodate multiple pallet levels, making it an efficient high-density option for operations where FIFO rotation is non-negotiable.
The key design consideration is matching roller type, track incline and lane depth to your pallet weight, base material and pick frequency. Pallets that are too light or have irregular bases can cause flow reliability issues if the system isn’t correctly specified.
Pallet live storage needs precise engineering around your pallet specification before anything else. An incorrectly specified incline or roller type creates flow reliability problems that are difficult to fix once the system is installed.
We assess your pallet dimensions, weights, base materials, pick rates and FIFO requirements to confirm pallet live storage is the right fit.
We design lane depth, track incline and roller configuration around your specific pallet and operational profile.
Professionally installed in line with AS4084:2023 and tested to confirm reliable pallet flow before handover.
We verify track incline, pallet travel speed and lane stopping performance before the system goes live.
We provide maintenance and reconfiguration as your pallet profile or operational requirements change
When stock rotation isn’t optional, manual FIFO management creates real operational risk. Pallet live storage removes that risk entirely by making correct rotation automatic, with no reliance on staff discipline or labelling systems.
If strict FIFO rotation is a requirement and you’re storing significant pallet volumes, pallet live storage is worth a serious look. Our team can assess your pallet profile and operational requirements, contact us to get started.
Pallet live storage, also called pallet flow or gravity flow racking, is a high density system where pallets sit on inclined roller tracks. Pallets are loaded at the high end of the lane and move forward under gravity to the picking face at the other end. Because loading and picking happen on opposite sides, stock rotates first in, first out automatically.
First in, first out, and it is the main reason to choose it. Pallets are loaded on one side of the run and picked from the other, so the oldest pallet in each lane is always the next one out. That makes it the high density option for date coded, perishable or batch tracked stock, where drive-in and push back racking are not suitable.
Both are high density lane based systems, but they rotate in opposite directions. Push back racking is loaded and picked from the same aisle and rotates last in, first out. Pallet live storage is loaded from one side and picked from the other, rotating first in, first out. Push back needs aisle access on one side only; pallet live storage needs it on both.
It suits a small number of product lines held in high volume, on consistent, stable, good quality pallets. Food, beverage and other date coded stock are the most common applications, because first in, first out rotation happens automatically. It is not a good fit for warehouses carrying many lines in small quantities, or for loads that are irregular or unstable.
Yes. Removing aisles reduces the refrigerated volume needed for a given number of pallets, and first in, first out rotation suits the date coded stock most cold stores carry. Components specified for low temperature operation need to be confirmed at design stage, because roller and brake performance changes in freezer conditions.
Lanes are fitted with speed controllers, or braking rollers, spaced along the track to regulate how quickly a pallet travels. A separator or pallet stop at the picking face holds the front pallet and takes the weight of the ones behind it, so the front pallet can be lifted off cleanly. Both are sized against the pallet weight and lane length. To assist the braking, it is desirable that the pallet weights are similar, otherwise you will have pallets that don’t move if the product is light or the pallets will mover too quickly if the are heavy and the system has been specified for lighter products.
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.
