Automated Pallet Storage and Retrieval System

Optimize Your Warehouse Operations with an Automated Pallet Storage and Retrieval System AS/RS. 

Are you tired of dealing with the inefficiencies, cost and space in your pallet warehouse storage methods? Do you find yourself constantly battling with labor and space constraints while struggling to meet KPIs and operational demands? If so, it’s time to revolutionize your warehouse operations with an automated pallet storage and retrieval system.

This technology can help optimize your storage capacity, improve labor requirements and productivity, and streamline your entire workflow. Eliminate costly and unreliable labor and see how a fully automated system will take care of all your pallet handling and warehouse management needs. From storing and retrieving pallets with precision to maximizing space utilization, these systems are designed to enhance your warehouse efficiency like never before.

Don’t let outdated storage methods hold you back from reaching your KPIs. It’s time to take your warehouse operations to the next level with an automated pallet storage and retrieval system.

Challenges in Traditional Pallet Handling Warehouse Operations

Traditional pallet handling warehouse operations often face several challenges that hinder efficiency and productivity. One of the major issues is the reliance on manual labor for tasks such as pallet storage and retrieval. This not only increases the risk of errors but also consumes a significant amount of time and resources. Additionally, manual handling can lead to damaged pallets and inventory, further impacting operations.

Another challenge faced by traditional warehouse operations is the limited space utilization. Manual storage methods often result in wasted space due to forklift congestion, inefficient putaway and poor organization. This can lead to increased storage costs and reduced capacity for incoming inventory. Moreover, inefficient space utilization can hamper the facility workflow and make it difficult to meet operational KPIs. These challenges highlight the need for a more advanced and automated solution to optimize warehouse operations.

What is an Automated Pallet Storage and Retrieval System?

An automated pallet storage and retrieval system is a technological solution that revolutionizes warehouse operations by automating the process of storing and retrieving pallets otherwise called Goods-to-Person.

There are three basic styles of technologies (described below) that utilize advanced robotics, software, controls, and mechanized hardware to seamlessly handle and manage pallets with precision and efficiency. These systems are capable of handling pallets of various sizes and weights. These systems are equipped with sensors and software that enable them to navigate within the warehouse, locate specific pallets, and retrieve or store them with utmost precision.

Moreover, these systems are integrated with warehouse management software, which acts as the brain behind the entire operation. The software enables real-time tracking, visibility, and monitoring of inventory, optimizes storage space utilization, and streamlines the entire workflow. With an automated pallet storage and retrieval system, warehouse operators can eliminate the reliance on manual labor, minimize errors, and significantly improve operational efficiency.

Types of Automated Pallet Storage and Retrieval Systems

Automated pallet storage and retrieval systems come in various types, each designed to cater to different warehouse requirements and operational needs. Let’s explore some of the most common types:

1. Automated Pallet Crane & Aisle or Unit Load AS/RS

   : This type of system is designed for handling full pallet loads. It utilizes stacker cranes to retrieve and store entire pallets in designated storage locations. The crane moves up and down the aisle to its proper location while the load handler moves up to the proper storage height location. When the crane and load handling device are at the correct storage or retrieval location (X and Y coordinate position) the system stores or retrieves the pallet onto the correct location. In some systems the crane stays in one aisle, in others the crane can move from lane to lane depending on the next transaction’s location. Unit Load AS/RS is ideal for warehouses with high storage density requirements, as it maximizes space utilization.

2. Automated Pallet Shuttle or Pallet Mole AS/RS

   : This system utilizes a cart type shuttle, lifts, and robot or mole device to store and retrieve pallets within the system. The pallet shuttle runs within a rack storage system. This rack storage system can be single or multiple levels high depending on a user’s specific requirements such as storage density, throughput and budget. When shuttle AS/RS systems run horizontally and a lift for vertical motion, they are known as 2 Dimension shuttles or 2D shuttles. When the shuttles run horizontally, and use a lift to travel vertically to span multiple floor levels, this is called 3-dimension shuttles or 3D shuttles. Often 3D shuttles utilize lifts, elevators to span a system’s height. A 3D shuttle system can utilize moles which run horizontally in one in one row moving the next pallet in or out of the aisle and is picked up by the shuttle to be delivered to its destination.

3. Automated Robotic-Based Pallet AS/RS:

   This system utilizes a combination of technologies to provide maximum flexibility and agility but sacrifices the high density or cube utilization that the other systems can achieve. This system will integrate transportation autonomous mobile robots (AMR) systems, tugger AMRs, forklifts and/or AMR forklifts depending on the number of pallets, pallet weight, facility height and transportation distance. These systems can provide total lights-out unit load or be that labor free automated pallet storage and retrieval systems.

These are just a few examples of the types of automated pallet storage and retrieval systems available. Every system has options, sub-systems and features to meet organizations’ exact requirements. Each system offers unique features and benefits, allowing warehouse operators to choose the one that best suits their specific needs and requirements.

Benefits of Implementing an Automated Pallet Storage and Retrieval System

Implementing an automated pallet storage and retrieval system can bring numerous benefits to your warehouse operations. Let’s explore some of the key advantages:

1. Up to 2/3 Reduced Labor Costs: Automated pallet storage and retrieval systems eliminate the need for manual labor in pallet handling tasks. By reducing labor requirements, warehouses can significantly cut down on labor costs, reduce the risk of human errors, and free up resources for other critical operations.
2. Increase Throughput by up to 2/3: With an automated system, the pallet storage and retrieval process is streamlined and highly efficient. The system can quickly locate and retrieve specific pallets, reducing the time spent on manual searching, forklift availability and deadheading. This results in faster order fulfillment, improved productivity, and higher customer satisfaction.
3. Up to 85% Space Utilization Improvement: Automated systems optimize space utilization by utilizing vertical storage and maximizing storage density. This allows warehouses to store more pallets in the same footprint, thereby reducing the need for additional warehouse space and lowering operational costs.
4. Increased Accuracy to 99.9%: Manual pallet handling methods are prone to errors, such as misplacement or damage. An automated system ensures precise handling and eliminates the risk of human errors. This results in improved inventory accuracy, reduced product damage, and enhanced overall operational efficiency.
5. Real-time Tracking, Visibility and Inventory Management: Automated systems are integrated with warehouse management systems (WMS) and warehouse execution systems (WES) software that enables real-time tracking and monitoring of inventory. This allows warehouse operators to have complete visibility over stock levels, inventory movement, and order fulfillment. Real-time data helps in making informed decisions and optimizing warehouse operations.
6. Eliminating or Dramatically Reducing Forklifts: Between forklift costs, maintenance, labor and often more importantly congestion, automated pallet storage and retrieval systems can do the work for you. From induction to storage, to retrieval and delivery to the dock doors… a forklift free environment can be created.

Implementing an automated pallet storage and retrieval system can transform your warehouse operations, leading to reduced labor, increased capacity, cost savings, and improved customer satisfaction. Optimizing warehouse operations is crucial for businesses looking to stay competitive in today’s fast-paced market. An automated pallet storage and retrieval system offers a revolutionary solution to overcome the challenges faced by traditional warehouse operations.

By implementing an automated system, you can optimize space utilization, improve productivity, and streamline your entire workflow.

If you would like to dive deeper into an automated pallet storage and retrieval system for your operations, schedule a free consultation.