ASRS System Types and Their Applications

Explore the world of Automated Storage and Retrieval Systems (ASRS) - from unit-load and mini-load systems to carousel solutions, vertical lift modules (VLMs), and shuttle systems. These innovative technologies are transforming logistics in manufacturing, distribution, and retail by boosting efficiency, accuracy, and space utilisation.

ASRS revolutionises warehouse operations by automating storage and retrieval, reducing labour costs, and optimising inventory management. These systems are designed to handle varying inventory types and speeds and ensure seamless material handling year-round.

Types of ASRS

Load-based Automated Storage and Retrieval System

Unit-Load ASRS Designed for heavy loads (up to 2500 kg), unit-load ASRS uses cranes in narrow aisles to store pallets or containers. With structures up to 30 metres high, these systems are ideal for warehouses handling large or odd-shaped goods. High-throughput systems can use multiple SRMs per aisle, while slower systems use fewer SRMs.

Mini-Load ASRS Mini-load ASRS stores smaller items like totes or cartons (under 50 kg). Its modular design allows heights between 8 and 12 metres, making it flexible for various warehouse sizes.

Micro-Load Stocker ASRS This compact system stores products in bins and retrieves them using an extractor, delivering items to the operator. Often integrated with other ASRS systems, it optimises space and reduces the need for conveyors—perfect for industries requiring fast picking and kitting.

Bot-Based ASRS

Shuttle-Based ASRS

Shuttle-based ASRS works in both FIFO and LIFO configurations, supporting deep or shallow-lane storage. Shuttles (Small robots) retrieve items from racks and return them to workstations. Ideal for warehouses with low ceilings or space constraints, such as cold storage, it can also be combined with manual labour or conveyors for efficiency.

Floor Robots ASRS

Floor robots transport portable shelving with inventory to operators, moving across facilities autonomously. This scalable system is suitable for slow to medium-moving inventory, with each shelving unit typically supporting up to 500 kg.

Carousel based Automated Storage and Retrieval System

Vertical Carousel

Vertical carousels use carriers on a vertical loop, much like a Ferris wheel, to store and retrieve items efficiently. Ideal for slow to medium-moving inventory, it delivers items to an ergonomic workstation when needed. It supports up to 750 kg per carrier and can be enhanced with light or voice-based picking for multiple orders.

Horizontal Carousel

Horizontal carousels rotate bins on an oval track, designed for slow to medium-moving inventory up to 100 kg. Installed in pods for high throughput, it optimises space and can be expanded with light or voice-based picking.

Miscellaneous

Vertical lift module ASRS

Vertical Lift Modules (VLMs) are ideal for high-ceiling environments, reaching up to 100 feet, where they safely handle heavy items. They consist of two columns of trays with a central mechanical extractor that moves vertically, similar to an elevator. The extractor retrieves and stores items by moving between trays, which are accessed via a control pad. This system supports both storage and retrieval operations, enhancing efficiency in warehouses.

VLMs are crucial in sectors like Food & Beverages, Pharma, and Cold Storage, optimising space and streamlining inventory management.

Conclusion

Automated Storage and Retrieval Systems (ASRS) are redefining logistics by significantly improving efficiency, accuracy, and space utilisation, saving up to 85% of floor space. With solutions like unit-load, mini-load, VLMs, and shuttles, ASRS caters to diverse operational needs, optimising inventory management and agility. According to McKinsey, businesses adopting ASRS report a 75% reduction in picking errors and a 66% increase in order fulfillment speed, driving customer satisfaction, reducing returns, and strengthening brand credibility.

Automated Storage and Retrieval Systems are no longer just an option but a critical advantage for businesses looking to stay ahead in today’s fast-paced logistics landscape.

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