Engineered to international FEM and EN standards, our comprehensive range supports dynamic carton flow, heavy-duty pallet staging, automated sortation, and modular assembly integration across Turkish manufacturing and logistics hubs.
Gravity flow shelving—commonly deployed as Carton Flow (for hand-picking, totes, and split-case operations) and Pallet Live Storage (for unitized pallet throughput)—operates on pure kinetic gravitational energy. By utilizing precision-inclined roller tracks angled between 2.5° and 4.0° (dependent on package tare, friction coefficient, and base rigidity), dynamic storage eliminates electric drive mechanisms while enforcing an absolute First-In, First-Out (FIFO) stock turnover policy.
In high-velocity distribution centers throughout Türkiye, where warehousing floor lease rates in Istanbul, Kocaeli, and Bursa have surged alongside nearshoring manufacturing expansions, static shelving systems consume excessive aisle space. Gravity flow engineering decouples replenishment from order picking: stock loaders work exclusively in the rear loading aisle, while picking personnel operate without vehicular interference in the dedicated retrieval aisle.
Operational Impact: Decoupled loading and extraction aisles slash picker transit paths by up to 48%, eliminate forklift-pedestrian collision hazards, and guarantee automatic queue progression without parasitic energy consumption.
Our dynamic roller profiles feature high-grade polypropylene or zinc-coated steel skate wheels mounted on cold-rolled structural steel side channels. When integrated with drop-in brake rollers and pneumatic or centrifugal speed controllers, our gravity lanes safely handle items ranging from delicate 200-gram pharmaceutical cartons up to 1,500-kilogram heavy euro-pallets without impact deformation.
Direct-contact centrifugal brake rollers maintain a uniform glide speed between 0.25 m/s and 0.35 m/s, neutralizing runaway accelerations in deep-lane pallet runs exceeding 15 meters in length.
Engineered to nest securely into standard teardrop, slotted, or Omega-beam selective racking without field welding. Adjustable clip brackets permit pitch modifications in 0.5-degree increments.
Mechanical entry and discharge separators relieve line pressure on the front extraction pallet, ensuring reach trucks or stackers withdraw unit loads without back-pressure friction or product binding.
A side-by-side engineering comparison designed for procurement leads, warehouse automation planners, and industrial supply chain directors evaluating dynamic racking installations.
| Performance Metric | Carton Gravity Flow (Light to Medium) | Pallet Live Storage (Heavy Duty) | Static Selective Shelving (Baseline) |
|---|---|---|---|
| Load Capacity Range | 10 kg to 50 kg per linear meter / tote | 500 kg to 1,500 kg per pallet position | 150 kg to 800 kg per shelf beam level |
| Standard Track Incline | 2.8° to 4.5° (Carton / Tote dependent) | 3.0° to 3.5° (Pallet base dependent) | 0.0° (Static horizontal planes) |
| Roller Track Architecture | Polycarbonate / POM wheels in aluminum track | Full-width steel rollers or triple-track zinc skate | Solid steel decking or timber wire mesh |
| Storage Density Efficiency | High (Up to 75% Cube Usage) | Ultra-High (Up to 85% Cube Usage) | Low to Moderate (40% Cube Usage) |
| Inventory Discipline | Guaranteed FIFO or LIFO (Push-back mode) | Strict First-In, First-Out (FIFO) | Unenforced / Random access dependent |
| Picking Cycle Acceleration | +40% to +60% picking lines per man-hour | +30% rapid pallet staging and dock loading | Baseline benchmark |
| Seismic Damping Index | Dynamic flexible roller dampening | Equipped with inertia-activated lock catches | Rigid structural anchor point transmission |
Turkey’s geographical position as the bridge between Europe, Central Asia, and the Middle East, coupled with the rapid implementation of the "Turkey Logistics Master Plan", demands high-density, earthquake-compliant storage infrastructure.
The concentration of e-commerce giants (Trendyol, Hepsiburada, Amazon TR) and third-party logistics (3PL) conglomerates in Dilovası, Gebze, and Tuzla requires ultra-fast split-case order picking. Our carton flow beds integrate directly with Pick-to-Light (PTL) optics and automated takeaway conveyor systems, driving split-case processing throughputs past 1,200 picks per operator hour.
Supplying Tier-1 sub-assembly operations for Oyak-Renault, TOFAŞ, and Ford Otosan demands strict Just-In-Time (JIT) and Just-In-Sequence (JIS) part feeding. Our heavy-duty carton flow and injection mold racks streamline small load carrier (KLT) boxes directly to assembly operators, eliminating side-rack buffer inventory and keeping assembly floor paths clear.
Perishable agricultural exports, dairy processors, and chemical distribution complexes operating through Alsancak and Mersin International Port require stringent FIFO compliance under sub-zero or humid ambient conditions. Our zinc-plated, corrosion-resistant pallet flow lanes guarantee that sensitive temperature-controlled inventory rotates before shelf-life expiration.
Because the major manufacturing centers of Istanbul, Bursa, and Kocaeli lie within the high-risk North Anatolian Fault Zone (Deprem Bölgesi), warehouse racking cannot be engineered as static furniture; it must perform as a structural framework under seismic lateral acceleration.
In accordance with TBDY 2018 (Türkiye Bina Deprem Yönetmeliği) and Eurocode 8 (EN 1998 / EN 15512), our gravity flow systems feature high-ductility upright cold-formed profiles, engineered baseplates with oversized Hilti/Fischer anchor bolts, and dual-plane cross-braced portal frames. Furthermore, our roller lanes are fitted with mechanical anti-lift safety tabs to prevent roller trays and stored pallets from dislodging during cyclical lateral seismic excitations.
Market forces, regional manufacturing relocations, and industrial land economics are transforming static warehouse designs into dynamic, energy-free automated storage systems.
Multinational European brands continue relocating buffer inventory hubs to Turkey to insulate supply chains against Suez and Red Sea transit disruptions. This requires high-turnover cross-docking facilities capable of storing, re-sorting, and dispatching cargo to the EU within 72 hours via overland TIR transport.
Prime warehouse rents in the Marmara basin have increased significantly over the past 36 months. Operators can no longer afford wide, non-productive forklift aisles. Gravity flow systems shrink aisle requirements by up to 60%, consolidating storage footprint into minimal square meters.
With Turkey's progression toward EU Green Deal carbon border adjustments (SKDM / CBAM), facilities must lower warehouse kilowatt consumption. Gravity flow offers an entirely passive, zero-electricity automated continuous conveying solution with virtually zero carbon footprint.
Operating our own specialized roll-forming lines, automated punching centers, and certified powder-coating facilities enables complete end-to-end control over structural steel tolerances, lead times, and global shipping logistics.
High-tensile structural coil steel tested for yield strength and elongation before fabrication starts.
Computerized multi-station cold roll formers ensure exact profile geometry and seamless beam interlocking.
High-speed repeatable hole patterns deliver 50mm and 75mm beam adjustment pitches for rapid field reconfiguration.
Eco-friendly hybrid polyester powder coating and knock-down export bundle crating for container shipping.
Exporting industrial racking systems demands precision container packing protocols. Our knock-down export engineering ensures that frames, beams, and pre-assembled roller trays pack flat into 40ft High Cube containers without void space loss, driving down ocean freight expense per pallet position.
We provide full export documentation support for Turkish customs clearance (Gümrük İşlemleri), including EUR.1 / ATR Movement Certificates where applicable, detailed packing lists, CE declarations, material mill test certificates (EN 10204 3.1), and comprehensive 3D assembly shop drawings.
Straightforward engineering and logistics insights covering custom clearance, earthquake codes, roller longevity, and system retrofits.
Our export shipping team handles full commercial documentation tailored to Turkish Customs Directorate (T.C. Ticaret Bakanlığı) standards. We furnish complete commercial invoices, detailed packing lists with HS code specifications (primarily under Chapter 7308 for steel structures), certificates of origin, and certified mill test reports ensuring smooth customs release at ports like Ambarlı, Gemlik, or Alsancak.
Yes. Our drop-in carton flow and pallet flow beds are engineered with universal mounting brackets designed to seat securely onto standard box beams, step beams, and Omega profiles. Our engineering team requires only your beam clear span, beam depth, upright profile pitch, and clear internal depth to manufacture bespoke, drop-in roller shelves that require zero on-site welding or drilling.
All structural designs adhere strictly to TBDY 2018 and EN 15512:2020. We analyze site-specific seismic coefficients based on coordinate ground acceleration data (Ss, S1) from AFAD's interactive earthquake hazard map. We configure heavy-duty column profiles (up to 2.5mm steel thickness), dual anchor baseplates, and longitudinal tie bracings to absorb lateral seismic energy without rack collapse.
Our heavy-duty steel rollers and high-impact virgin POM/polycarbonate skate wheels feature sealed precision bearings rated for over 100,000 continuous operating cycles under rated capacity. In demanding, multi-shift e-commerce and automotive operations, the typical operational lifespan exceeds 10 to 15 years with minimal maintenance limited to routine visual cleaning and guide rail alignment checks.
We calibrate each project's roller pitch and gradient according to your specific tote or carton base footprint. For pallet flow, we utilize three-track full-roller arrays and test bottom board deflection against FEM 10.2.02 tolerances. Where wooden pallets exhibit uneven bottom skids, full-width steel rollers or auxiliary guide center rollers ensure continuous travel without tracking derailment.
Standard custom-engineered production runs require 2 to 3 weeks depending on project tonnage. Ocean container shipping transit to Turkish primary ports (Ambarlı, Mersin, Gemlik) typically spans 10 to 16 days. For urgent expansion programs, staggered container dispatches ensure your installation crews receive structural frames first, followed by drop-in roller shelves.
Send our structural team your warehouse CAD floor plan, ceiling clear heights, SKU weight distribution, and handling equipment specs. Receive an optimized 3D layout, load-capacity matrix, and CIF/FOB pricing within 48 hours.