Racking & Shelving Specialists — Hamriyah Free Zone, Sharjah · Serving the UAE & GCC
Engineered from premium structural steel with resilient powder-coated finishes, our modular systems seamlessly integrate into existing UK warehouse footprints, fast-paced fulfilment centres, and dynamic carton live picking lines.
Carton Live Storage (CLS)—commonly termed carton flow or dynamic picking bed racking—operates on an unpowered, gravity-fed inclined wheel or roller track bed that separates loading and picking tasks into two discrete, non-interfering aisles.
In modern high-throughput UK distribution environments, traditional static shelving produces profound labor inefficiencies. Pickers spend up to 70% to 75% of their total cycle time navigating aisles rather than selecting items. Carton Live Storage completely overturns this dynamic by consolidating the pick face. Cartons, totes, or bins are replenished from the rear replenishment aisle (charging side), rolling gently by gravity down inclined tracks to the forward retrieval aisle (picking side). As the front carton is picked, the behind carton immediately indexes into position via controlled gravity, guaranteeing seamless First-In, First-Out (FIFO) stock turnover.
Available in cold-rolled galvanised steel frames fitted with high-impact thermoplastic polypropylene cylindrical rollers or full-width steel rollers. Engineered for low starting resistance ($C_r \le 0.02$) and quiet operation.
Tool-free, clip-in guide dividers engineered from spring steel or rolled galvanised sheet prevent carton migration and cross-lane friction, ensuring high-speed picking accuracy even when handling mixed SKU dimensions.
Features an adjustable drop-tray / presentation shelf tilted forward between $5^\circ \text{ and } 15^\circ$. This orientation presents open-top cartons and split-case containers directly into the picker's natural line of sight and grip.
| Engineering Parameter | Light-to-Medium Picking | Heavy-Duty Industrial Duty | Cold Store & Deep Freeze |
|---|---|---|---|
| Target Package Type | Cardboard cartons, Euro-boxes (KLT), lightweight totes | Heavy plastic crates, corrugated master shippers, metal bins | Frozen food cartons, pharmaceutical cold totes, food crates |
| Roller Track Diameter & Material | $\varnothing 28\text{mm}$ High-Impact Polypropylene | $\varnothing 38\text{mm}$ Zinc-Plated Carbon Steel | $\varnothing 28\text{mm}$ Low-Temp Impact Modified Copolymer |
| Load Rating Per Linear Metre | $100\text{ kg} - 150\text{ kg} / \text{m}$ | $250\text{ kg} - 450\text{ kg} / \text{m}$ | $120\text{ kg} - 200\text{ kg} / \text{m}$ |
| Incline Gradient ($\theta$) Range | $3.5\% - 5.5\%$ ($2^\circ - 3.2^\circ$) | $5.0\% - 8.0\%$ ($2.9^\circ - 4.6^\circ$) | $4.0\% - 6.5\%$ (Counteracts cold condensation) |
| Operating Temperature | $-5^\circ\text{C to } +45^\circ\text{C}$ | $-10^\circ\text{C to } +50^\circ\text{C}$ | $-30^\circ\text{C to } +20^\circ\text{C}$ Continuous |
| System Integration Suitability | Standalone Beds / Longspan | Pallet Rack Under-Slung | Stainless / Galvanized Steel |
From the historic logistics clusters of the East Midlands to coastal distribution gateways, UK supply chains demand maximum cubic volume density and ultra-responsive pick speeds.
Concentrated around Daventry, Northampton, Lutterworth, and Magna Park, mega-distribution centres manage hundreds of thousands of retail SKUs. Integrating carton live beds beneath pallet racking allows pallet reserve storage overhead while maximizing high-velocity ground-level piece picking for next-day UK parcel carriers.
Automotive assembly plants and tier-1 component suppliers throughout Solihull, Sunderland, and Coventry depend on Carton Live Storage for Just-In-Sequence (JIS) line-feeding. Color-coded roller tracks with mechanical separator stops present hardware and sub-assemblies directly to assembly operatives with zero parts mixing.
Pharmaceutical wholesalers serving NHS supply chains enforce stringent batch-traceability and strict expiry control. Carton Live Storage guarantees physical First-Expired, First-Out (FEFO) and FIFO compliance, preventing stock entrapment and ensuring lot integrity in compliance with MHRA Good Distribution Practice (GDP).
With UK commercial refrigerated warehouse electricity costs at historic highs, maximizing storage density in chilled ($+2^\circ\text{C}$ to $+4^\circ\text{C}$) and frozen ($-20^\circ\text{C}$ to $-25^\circ\text{C}$) facilities is critical. Our low-temperature polymer roller tracks operate smoothly without lubrication freeze-up, eliminating wasted cubic air space.
Structural macroeconomic forces in the United Kingdom—including prime industrial rent escalations and statutory minimum wage rises—are accelerating the shift toward gravity-powered live storage systems.
With prime warehouse space in London Heathrow, the M25 ring, and the Midlands frequently exceeding £12 to £22 per sq ft, expanding building footprints is financially prohibitive. Carton live systems dramatically condense dynamic pick faces, enabling operators to achieve up to 300% more SKU facings across existing aisle dimensions without facility extensions.
UK logistics operators are combining carton live racking with Autonomous Mobile Robots (AMRs). Operatives pick from live gravity lanes and immediately load onto waiting AMR decks stationed along pick aisles. This hybrid approach eliminates picker transit completely while avoiding the massive capital expenditure of fully automated AS/RS cranes.
In step with the UK Government's legally binding Net Zero targets and corporate ESG scopes, logistics directors favor zero-power gravity transport over powered belt conveyors. Carton live storage requires zero electricity to operate, providing indefinite, silent horizontal stock advancement utilizing ambient gravitational potential energy.
From initial dimensional audits to UK site handover, our engineering team ensures seamless design, structural validation, and flawless installation with minimal operational downtime.
Rigorous SKU velocity profiling, packaging dimensional scans, tote material friction tests, and warehouse clear height analysis.
Detailed 3D CAD modeling, rack upright loading calculation, gravity gradient simulations, and integration design with existing pallet racks.
Automated roll-forming from certified high-tensile steel, robotic welding, electrostatic powder-coating, and roller track run-out tests.
Direct consolidated shipping to major UK ports (Felixstowe, Southampton, London Gateway), customs clearance management, and staged site delivery.
SEMA-aligned installation guidelines, full slope verification, live package testing, load warning notice installation, and safety sign-off.
Rooted in 36 years of international industrial storage design and structural engineering, we deliver certified safety, precision craftsmanship, and bespoke adaptability to the British intralogistics sector.
Over three decades of precision manufacturing for global supply chains. We bring deep, field-tested technical wisdom to complex UK warehouse layouts, resolving load deflections and seismic considerations with mathematical precision.
All load-bearing profiles are designed in accordance with BS EN 15512 (Steel Static Storage Systems) and conform to Storage Equipment Manufacturers’ Association (SEMA) tolerances, ensuring hassle-free UK SARI safety sign-offs.
Our carton live roller beds feature universal bracket geometry compatible with all major UK rack upright manufacturers (including Dexion, Link51, Apex, Apex Linvar, Stow, and AR Racking), facilitating effortless brownfield retrofits.
Established freight logistics chains ensuring reliable delivery into major UK ports. Comprehensive export packaging protects galvanized roller tracks and pre-assembled beds against sea-air corrosion and handling stresses.
Key structural, regulatory, and commercial considerations addressed by our Senior Storage Systems Consultants.
Yes. All structural steel components, uprights, intermediate support beams, and dynamic roller track frames are manufactured in compliance with BS EN 15512 (Steel Static Storage Systems) and adhere to the design tolerances set by the UK Storage Equipment Manufacturers’ Association (SEMA). Furthermore, installations undergo full load-deflection verification ($L/200$ deflection limits for dynamic beds) to satisfy UK SARI (SEMA Approved Racking Inspector) annual warehouse safety audits.
The standard operational gradient is between 3.5% and 6.0% ($2.0^\circ \text{ to } 3.5^\circ$), governed by package base characteristics and total unit weight. Lightweight corrugated boxes with slight base sag require steeper gradients (approx. 5.0% - 6.0%) and tighter roller pitches (16mm - 25mm) to distribute load. Rigid plastic Euro-totes (KLT) glide efficiently at 3.5% - 4.0%. For mixed weight loads running along long lane depths, we install centrifugal brake rollers along the track to regulate maximum rolling speed and prevent impact damage at the pick stop.
Absolutely. Our universal drop-in and clip-on bracket systems are custom-punched to mate with all standardized European and UK pallet rack teardrop or hook-slot upright profiles (such as Apex, Link51, Dexion, AR Racking, and Stow). You can convert the ground or lower levels of your existing pallet racking into ultra-dense carton live picking bays, while maintaining standard pallet storage across upper beam levels for bulk reserve replenishment.
Standard custom-engineered carton live modules typically carry a 3 to 4-week factory manufacturing window. Direct consolidated ocean shipping to major UK container ports—including Felixstowe, Southampton, and London Gateway—takes approximately 28 to 35 days. We furnish full UK customs declarations, bills of lading, and certificate of origin documentation, ensuring completely seamless door-to-door delivery direct to your distribution centre.
Under the UK Construction (Design and Management) Regulations 2015 (CDM 2015) and HSE manual handling guidelines, warehouse duty holders are legally required to minimize repetitive strain injuries and heavy lifting. By presenting pick cartons at an inclined angle directly at ergonomic waist height (the "golden zone"), operatives avoid deep bending or overhead stretching. Crucially, the total physical separation of forklift replenishment from operative pedestrian picking paths eliminates the primary source of warehouse collision fatalities.
Due to the substantial UK National Living Wage rate increases and soaring industrial real estate rates, most 3PL and multi-channel fulfillment operations achieve complete capital payback within 9 to 14 months. Payback is driven by two measurable operational gains: a 65% - 75% reduction in picker walking travel hours, and a 25% - 35% reclamation of usable warehouse floor area through aisle consolidation.
Send your warehouse dimensions, pallet & carton dimensions, and picking profile data. Our storage design engineers will deliver a comprehensive 3D system layout, load capacity study, and competitive factory-direct supply quotation.
Connect with our technical intralogistics team for engineering layout assistance, technical specifications, and factory direct quotations.
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