Kosovo Warehouse Picking Upgrade with 100 Sets of Carton Flow Rack and Central Conveyor Line

Kosovo Warehouse Picking Upgrade with Carton Flow Rack and Central Conveyor

This case study details how a distribution client in Kosovo upgraded an aging warehouse into a fast, ergonomic order-picking operation by installing 100 sets of carton flow rack on both sides of a central conveyor line.

Customer Background

The customer is a growing distribution company based in Kosovo, serving retailers and small wholesalers across the region. Their product mix contains a large number of fast-moving, small to medium-sized cartons, which made manual order picking slow and labor intensive. To support rising order volumes, the customer decided to modernize an existing old warehouse instead of building a new facility.

Operational Challenges

• Limited usable space inside an old warehouse with a fixed building structure.
• A high number of SKUs requiring quick, repeated access for picking.
• Slow manual picking and long walking distances for operators.
• The need to handle carton loads of 300-500 kg per level safely.
• A tight budget that required a practical upgrade rather than a full rebuild.

The Solution: Carton Flow Rack Flanking a Central Conveyor

To match the existing warehouse layout, we supplied 100 sets of carton flow rack arranged on both sides of a central conveyor line. Operators pick items directly from the inclined flow lanes and place completed orders onto the conveyor, which carries orders toward the packing and dispatch area. This layout removes unnecessary walking and creates a clean, one-way picking flow.

Each bay was designed as 2700 mm long, 2500 mm deep and 2600 mm high, with four picking levels. Every level supports 300-500 kg, making the system suitable for a wide range of carton weights. The inclined roller lanes let cartons flow forward automatically, so the next item is always presented at the picking face for fast, ergonomic access.

Technical Specifications

Layout Highlights

• Carton flow rack positioned on both sides of the conveyor line for balanced picking on each side.
• Conveyor in the middle acts as the order transport spine, reducing internal traffic and travel time.
• Four levels per bay fully use the 2600 mm working height for dense but accessible storage.
• Gravity roller lanes keep products at the picking face, supporting first-in first-out rotation.

Results and Benefits

• Order picking became faster and more consistent by removing unnecessary walking.
• Storage density increased within the same old warehouse footprint.
• Ergonomic presentation of goods reduced operator fatigue and picking errors.
• The central conveyor improved order flow toward packing and dispatch.
• Four levels and 300-500 kg capacity per level handled the full carton range comfortably.

Why This Solution Works for Old Warehouses

Old buildings often have irregular columns, limited clear height and restricted floor area. Carton flow rack is flexible and modular, so it can be configured around these constraints. By combining flow lanes with a central conveyor, the customer gained a modern picking operation without the cost and disruption of moving to a new site.

Start Your Project

Whether you are upgrading a legacy warehouse or planning a new picking zone, our team can design a carton flow rack and conveyor layout around your exact dimensions and load requirements. Contact us today to request a free layout drawing and factory quotation.