Inside Logistics

Mallard opens new carton flow rack plant

Increased flow rack demand thanks to e-commerce led to need for new facility

July 24, 2019

Sterling, Illinois – Mallard Manufacturing, manufacturer of gravity flow storage products, has opened  a new production facility in Maquoketa, Iowa.

The 30,000 sq. foot facility opened its doors on July 1st, 2019 as a dedicated carton flow rack manufacturing site.

The need for a new facility is largely due to the increased market demand for carton flow rack to handle faster, smaller, more customized order fulfillment. Carton flow rack is recognized as an affordable, space-saving storage solution for case, carton and each-pick applications.

“The new Iowa plant gives us the added capacity we need to meet increased order volume of carton flow rack and accessories,” says Kevin Risch, president of Mallard Manufacturing.

“The site is equipped with high-speed punching equipment and automated workstations to ensure optimal processing efficiency, accuracy and lead times,” adds Risch.

Six types of Mallard carton flow will be produced in the Iowa facility. The style selected by customers is mostly dependent upon the size and style of inventory that will be stored in the flow system.

Dyna-Flo is a  wheeled carton flow product from Mallard and Cart-Trak is their leading roller system. Wheeled systems accommodate inventory of different sizes within the same picking bay, whereas roller systems are more suited for same-sized inventory. Mallard’s Dyna-Flo HD is for cases, cartons, packaging or totes weighing up to 50 lbs. per item. Beverage, wine & spirits, dairy are often prime HD inventory.

Other Mallard carton flow products include Dyna-Deck which is a replacement system for old or ineffective carton flow products, Flo-Guide which is a flanged-wheel system for items that might shift in the lane, and economy products Rack-Trak and Econ-Flo.