Types of AS/RS Systems
Vertical Lift Modules (VLMs)
Automated vertical storage with retrievable trays. Height up to 35', capacities to 1,100 lbs per tray. Goods-to-person picking with 99.9%+ accuracy.
Horizontal Carousels
Rotating oval track systems bringing items to operator. Pod heights 6'-12', lengths up to 100'+. Multiple carousels can work as integrated picking systems.
Vertical Carousels
Vertical ferris wheel design maximizing ceiling height. Footprint as small as 5'×5', heights up to 30'. Ideal for small parts and slow-moving inventory.
Unit Load AS/RS
High-bay automated systems for pallets and large containers. Crane-based retrieval systems with capacities from 1,000-4,000 lbs per pallet position.
Mini-Load AS/RS
Automated systems for totes, bins, and small containers. High-speed stacker cranes with pick rates up to 400+ lines per hour for e-commerce fulfillment.
Robotic Storage
Grid-based robotic systems with mobile robots retrieving bins from high-density grids. Scalable systems that adapt to demand fluctuations and seasonal peaks.
Key Benefits & ROI
- Space Savings: Reduce storage footprint by 60-85% versus static shelving
- Labor Reduction: Eliminate travel time - bring products to operators
- Picking Accuracy: 99.9%+ accuracy with light-directed picking
- Inventory Control: Real-time tracking and cycle counting capabilities
- Throughput: Increase picking rates 2-5x over manual methods
- Ergonomics: Deliver items at optimal picking height, reduce injuries
Vertical Lift Modules (VLMs)
VLMs are the most popular AS/RS solution for small to medium parts storage. Items are stored in trays that are automatically delivered to an access opening at the optimal ergonomic height.
VLM Advantages
- Maximum Density: Utilize 90%+ of available height
- Flexible Storage: Adjustable tray heights accommodate various part sizes
- Fast Retrieval: Average retrieval time under 30 seconds
- Inventory Management: WMS integration for real-time inventory control
- Security: Controlled access prevents unauthorized parts removal
- Clean Storage: Enclosed system protects parts from dust and contamination
VLM Applications
- Manufacturing: Production parts, MRO supplies, tooling storage
- Distribution: Small parts picking, e-commerce fulfillment
- Healthcare: Pharmaceutical storage, medical device inventory
- Automotive: Service parts, dealership inventory management
- Aerospace: Critical parts storage with full traceability
Horizontal Carousel Systems
Horizontal carousels rotate bins and shelves to the operator, eliminating walking and searching time. Multiple carousels can be integrated for batch picking operations.
Carousel Benefits
- High Throughput: Simultaneous picking from multiple units
- Batch Picking: Pick multiple orders in single pass
- Flexible Heights: 6' to 12' pod heights available
- Modular Design: Add or relocate carousels as needs change
- Cost Effective: Lower cost per position than VLMs
Integration & Software
Modern AS/RS systems integrate seamlessly with existing warehouse management systems, ERP platforms, and business applications.
Software Features
- Inventory Management: Real-time stock levels and locations
- Pick Optimization: Batch orders and optimize pick sequences
- Cycle Counting: Automated inventory verification
- Reporting: Performance metrics and productivity analysis
- Security: User access controls and transaction logging
- Integration: APIs for ERP, WMS, and e-commerce platforms
System Sizing & Configuration
AS/RS systems are configured based on your inventory characteristics, throughput requirements, and available space.
VLM Specifications
- Height: 8' to 35' available
- Width: 4' to 14' internal width
- Depth: 2' to 4' tray depth
- Tray Capacity: 110 to 1,100 lbs per tray
- Number of Trays: 40 to 200+ trays per unit
Carousel Specifications
- Pod Height: 6' to 12' standard
- Track Length: 20' to 100'+ ovals
- Carriers: 20 to 120+ carriers per unit
- Load Capacity: 500 to 1,200 lbs per carrier
- Speed: Variable speed controls
ROI Analysis & Payback
AS/RS systems typically provide ROI through labor savings, space reduction, and improved accuracy. Most installations achieve payback in 18-36 months.
Cost Justification Factors
- Labor Savings: Reduce picking labor by 50-80%
- Space Savings: Defer building expansion or relocation
- Accuracy Improvements: Reduce error costs and returns
- Inventory Reduction: Better visibility reduces safety stock
- Productivity: Increase throughput with same workforce
Installation & Project Management
AS/RS installations require careful project planning, site preparation, and integration with existing systems. Our experienced team manages every aspect of your project.
Project Process
- Analysis: Inventory study and throughput analysis
- Design: System configuration and layout design
- Engineering: Structural, electrical, and software specifications
- Installation: Site preparation, equipment installation, testing
- Training: Operator and maintenance training programs
- Support: Ongoing maintenance and system optimization
Industry-Leading Systems
We partner with multiple AS/RS manufacturers, allowing us to specify the optimal system for your specific requirements and budget.
Frequently Paired Solutions
Automated storage maximizes density and throughput when integrated with these advanced systems:
Selective pallet rack offers direct access to every stored pallet position.
Pallet conveyors automate heavy load transport between storage and shipping areas.
Warehouse racking maximizes vertical storage density and organization.
Modular buildings create enclosed office and production space within facilities.
Pick modules create organized picking zones with integrated storage and conveyance.
In-motion scales weigh products without interrupting conveyor throughput.
Industries We Serve
High-speed fulfillment infrastructure for online retail operations.
Sanitary and efficient processing and distribution systems.
Clean, controlled environments for pharmaceutical manufacturing and storage.
Assembly, parts handling, and manufacturing systems for automotive production.