Full & Split Roller Pallet Flow Racking

Full and split-roller pallet flow racking

TYPE: Pallet Flow Racking and Case Flow Racking Systems

MODEL: Full and Split Roller Pallet Flow Racking

The 2.5” diameter full roller pallet flow offers even greater surface coverage and rust-resisting galvanized rollers and rails than its contemporaries. It is a perfect solution for non-standard pallets including plastic pallets, large bins, extra-long pallets, drums, etc.

Ideal for ALL Pallet Racking System Types

Full roller pallet flow rack is the most flexible type of pallet flow racking, ideal for a variety of pallet sizes and warehousing needs.

To keep costs down, vendors often change pallet configurations; distributors then have to adjust their racking systems. Full-width pallet rack roller lanes are a great solution to this problem. As pallet configurations change, the system design will remain stabilized.

Applications that require additional capacity are better suited for split-roller pallet flow rack. Heavier pallets can cause minor deflection in full-width rollers which can negatively affect flow. Split-roller racking is also ideal for extra-wide, unwieldy loads. The number and spacing of flow rails are dependent on the dimensions and weight of the load.

All full and split-roller pallet flow rack designs are engineered and built using heavy-duty bearings, axles, tube, and side channels. Both are designed with maintenance in mind, so if damage occurs, replacement components can easily be installed.


  • Accommodates all pallet sizes
  • Adaptable to all major manufacturers’ rack
  • Custom mounting brackets for secure, low-profile, or heavy-duty use
  • Minimal maintenance
  • Allows First In, First Out (FIFO) rotation
  • Gravity-based/no power required


  • Rollers available: 1.9” / 2.5” diameter
  • Typical Axles: 5/16” bolt, 7/16” hex
  • Capacities range from 260 lbs - 350 lbs per roller
  • Between frame dimensions range from 4”- 60”

2.5 Full Roller Pallet Flow Racking

2.5 Full Roller Pallet Flow

The new 2.5" Full Roller Pallet Flow, provides a highly durable racking solution, combined with greater surface coverage and rust resistant roller and rails.  The out-to-out surface keeps pallets moving in a steady, consistent manner.  The 2.5" roller lane can be equipped with optional full-width drum speed controllers.  The full width controllers are mounted within the lane in-between the rollers(instead of underneath or dropped in) to provide greater braking coverage for steady, safe pallet indexing.

  • Ideal for plastic and non-standard pallets
  • Full-width drum controller maintains safe, consistent pallet speed
  • Larger rollers can provide greater capacity & increased roller spacing/cost-savings
  • Galvanized rollers and rails are durable & rust resistant
  • Heavy-duty, safety yellow ramp stops assure a safe landing at the pick aisle

Options for Full and Split Wheel Roller Pallet Flow Racking

Full and split pallet flow systems can be equipped with accessories to help support the functionality of the racking system.

  • Entry guides provide visual guides for forklift operators to load pallets evenly in the racking lane.
  • Speed controllers can be fitted based on your load specs to help control and track the flow of pallets down lane.
  • Bolt-on ramp stops can slow your pallet to a safe approach at the pick-face and help keep the pallet from pitching forward into the aisle.  Additionally, they are bolted on to the rack face, there is no need to replace the whole lane should one be damaged.

For more information on Full and Split Roller Pallet Flow Racking or for a pallet flow racking consultation, please contact a Thomas Conveyor & Equipment Automation Engineer at 800 220 0086 or click on the Contact Us button above.

QUESTIONS? CALL 844-220-0086