A guide to automated storage and retrieval systems (with FAQs)

Automated storage and retrieval systems (ASRS) are primarily utilised in manufacturing and distribution centers.

These systems streamline operations by replacing traditional shelving racks, further saving significant floor space, improving employee safety and boosting productivity.

In this article, we’ll explore the common types of automated storage and retrieval systems (ASRS), guide you on how to select the ideal warehouse technology for your operations and introduce you to the advanced ASRS solutions offered by Modula Australia.

What Is an Automated Storage and Retrieval System (ASRS)?

An automated storage and retrieval system (ASRS) is an innovation that stores, retrieves and delivers goods to warehouse employees.

Computers or robots control ASRS to replace large shelving areas. This allows ASRS to save floor space, improve workplace safety and boost productivity, among other benefits.

You can customise this automated solution to fit any size requirement through cube storage, robotics, carousels and shuttles.

In addition, a warehouse management system (WMS) oversees all these components to ensure efficient operation.

Who Invented Automated Storage and Retrieval Systems?

The technology known today as automated storage and retrieval systems (ASRS) originated with Demag, a precursor to Dematic.

This foundation of innovation continues to improve modern high-bay warehouses and optimises material handling.

Categories of Automated Storage and Retrieval Systems

ASRS technologies fall into three main categories, distinguished by their delivery methods:

1. Shelf-Based Picking ASRS: These systems deliver an entire shelf or tray of products to the warehouse staff.
2. Bin-Based Picking ASRS: These solutions bring an individual bin or tote of products directly to the warehouse operator.
3. Robotic Picking: These robots transport inventory to warehouse employees.

Types of Automated Storage and Retrieval System (ASRS) Technologies

From vertical carousel modules to floor robots and beyond, here are the different types of automated storage and retrieval systems to help increase throughput and optimise your warehouse operations.

1. Vertical Carousel Module (VCM): A vertical carousel module is an automated storage and retrieval system (ASRS) that features carriers on a closed-loop vertical track within a metal enclosure. It moves inventory in a vertical loop similar to a Ferris wheel, rotating shelves to deliver items directly to the operator. This solution maximises vertical space and efficiency.
2. Horizontal Carousel Module (HCM): A horizontal carousel module is an automated storage and retrieval system (ASRS) that consists of a horizontal oval track. It transports items horizontally and operates like a conveyor belt that transports stored items to the warehouse operator. This system efficiently utilises horizontal space and speeds up item retrieval.
3. Vertical Lift Module (VLM): A vertical lift module (VLM) is an ASRS that brings goods directly to the warehouse operator using the goods-to-person principle. Unlike a vertical carousel, the VLM is equipped with an advanced design allowing items to be retrieved individually without rotating the entire inventory.
4. Vertical Buffer Modules (VBMs): Compact automated storage systems that buffer and store items vertically, optimising space and improving retrieval times.
5. Mini-Load ASRS: Mini-load ASRS, or tote-stacking and case-handling ASRS, manage lighter loads up to 35 kg. These systems are ideal for storing and retrieving cartons, trays or totes in small facilities with a large variety of stock keeping units (SKUs).
6. Unit-Load ASRS: Unit-Load ASRS systems keep and move bulky and heavy items, such as pallets and cases. They can handle loads ranging from 500 to 2,500 kg and reach heights of up to 161 meters. The two types of unit-load ASRS include movable-aisle and fixed-aisle cranes.
7. Robotic Shuttle-based ASRS: Shuttle-based ASRS utilise a robotic shuttle to automatically deliver items. These systems operate at high speeds, handling 200 to 700 lines per hour. They can manage totes, trays, and cases weighing between 16 and 45 kg.
8. Robotic Cube-based ASRS: Robotic cube-based storage systems use a three-dimensional grid to organise and access items. Items are kept in stacked bins within these cubes. Smart robots navigate atop the grid to pick and deliver bins to workstations.
9. Floor Robots (AGVs/AMRs): Floor robots, or automated guided vehicles (AGVs) or autonomous mobile robots (AMRs), transport inventory within your warehouse to enhance efficiency and reduce employee travel time. You can use these robots to move bins, boxes and small parts.
10. Micro-Load Stocker: A micro-load stocker features robots that move across a dense storage grid, storing and retrieving inventory bins to transport them to conveyors or workstations efficiently. It’s ideal if your warehouse operations require an ASRS for sequencing, buffering and point-of-use goods.

Key Benefits of Automated Storage and Retrieval System

Automated storage and retrieval systems offer a plethora of benefits that can significantly improve your warehouse operations.

Some key advantages include:

1. Optimise Space: ASRS utilise vertical and horizontal space more efficiently than traditional storage methods, reducing the footprint needed for storage and enabling more products to be stored in a smaller area.
2. Improve Productivity: ASRS can significantly speed up warehouse processes, allowing for quicker response times and higher throughput.
3. Boost Accuracy: ASRS can help reduce human error in picking and placing items, enhancing inventory accuracy and reducing costly mispicks and product returns.
4. Enhance Workplace Safety: ASRS can help minimise the risk of workplace injuries, such as overexertion or falls, by minimising the need for workers to manually retrieve items — especially from high or hard-to-reach places.
5. Minimise Labour Costs: ASRS reduces the need for manual labour in repetitive tasks, which can lower labour costs and mitigate issues related to labour shortages, such as high turnover rates.
6. Improve Inventory Management: ASRS systems are often integrated with warehouse management systems (WMS), providing real-time inventory data that further helps with better inventory control and management.
7. Increase Security: ASRS can improve security and reduce theft or damage to inventory, thanks to access restrictions and automated monitoring systems that track and log each activity.
8. Achieve Sustainability: Modern ASRS are designed to be energy efficient, often using less energy than traditional systems, especially in controlled environments like cold storage.
9. Scalability: ASRS can be scaled up or down based on your business needs, making them a flexible solution for changing consumer behavior.

How to Choose the Right Automated Storage and Retrieval System for Your Warehouse

Choosing the right automated storage and retrieval systems for your operations requires different key considerations to make sure you select a system that aligns with your business needs, throughput goals and budget.

Here’s how you can approach the decision-making process:

1. Assess your inventory needs: Consider the size, weight and type of items you need to store. Different ASRS are better suited for different item types, such as pallets, cases or individual parts. Then, evaluate the quantity and diversity of your inventory. High-volume, low-variety items might benefit from different systems compared to operations with low-volume, high-variety items.
2. Analyse space constraints: Understand the physical space in your facility so you can expand or reconfigure the system as your business grows or needs change.
3. Consider throughput requirements: Determine how quickly you need to retrieve inventory. For example, systems like micro-load stockers are suitable for high-speed retrieval of small items. While larger, automated storage and retrieval systems can manage bulkier items or larger quantities.
4. Evaluate integration and compatibility: Check the compatibility of the ASRS with your existing warehouse management systems (WMS), enterprise resource planning (ERP) systems and other automation technologies. Ensure the ASRS can integrate seamlessly with your current and future technological infrastructure.
5. Review your budget and potential ROI: Consider the upfront costs of different ASRS types. More complex systems, such as robotic cube storage may require higher initial investments. Calculate potential savings in labour, time and inventory accuracy. Weigh these against the initial and ongoing costs to determine the projected return on investment (ROI).
6. Analyse supplier reliability and support: Select a supplier renowned for their reliability and experience within your specific industry. Opt for a vendor that prioritises customer-centric support and maintenance services, as the availability of parts and services can significantly affect system uptime.

What Is the ROI for ASRS?

Modula Australia’s automated storage and retrieval systems can deliver a return on investment (ROI) within six to 18 months.

This quick payback period for our Modula solutions justifies the investment.

The cost of your ASRS depends on the equipment, software, controls, delivery, installation, employee training and scheduled maintenance.

Explore Cutting-Edge Automated Storage and Retrieval Systems at Modula APAC

At Modula APAC we can help transform your warehouse operations by securing your inventory, boosting productivity and increasing efficiency.

Our automated vertical lift modules (VLMs) leverage ceiling height to maximise your facility’s footprint. They provide easy and secure access to inventory, creating a safer environment for your warehouse operators.

We offer three types of vertical lift modules (VLMs) tailored to meet diverse storage needs:

1. The Modula Lift: This versatile automated solution is ideal for storing products, components, and spare parts across various industries. It’s available in a wide range of sizes and storage capacities, with thousands of customisable configurations to meet specific requirements.
2. Modula Slim: Perfect for spaces with limited floor area but needing flexible vertical storage. Using the same advanced technology as The Lift, The Slim offers enhanced productivity, improved picking accuracy, and better inventory management in a compact design. It’s especially suited for storing small items like containers, spare parts, coils, and bottles.
3. Modula NEXT: Our most advanced generation of lift modules, Modula NEXT prioritises safety in automated picking. It features a specially designed bay that opens only the compartment needed for picking, reducing the risk of errors and lost items, and boosting warehouse efficiency.

For facilities with limited ceiling height that require high-speed picking, consider investing in our Modula Horizontal Carousel.

If you’re ready to take your warehouse efficiency to the next level, consider integrating one of our advanced automated storage and retrieval systems.

FAQs About Automated Storage and Retrieval Systems (ASRS)

Which industries use automated storage and retrieval systems?

ASRS is widely used in different industries, such as manufacturing, retail, eCommerce, pharmaceuticals and more.

Here’s a detailed look at how different industries utilise these systems:

1. Manufacturing: In manufacturing, ASRS helps manage raw materials, components and finished products. The precision and speed offered by these systems minimise errors, reduce labour costs and improve inventory control.
2. Retail: Retailers use ASRS to optimise warehouse space and respond promptly to changing market demands. This automation is particularly beneficial in handling seasonal spikes in demand.
3. eCommerce: For eCommerce, speed and accuracy in order fulfillment are essential. ASRS allows for rapid picking, packing and shipping processes, which enhances customer satisfaction by ensuring quick delivery times.
4. Pharmaceuticals: In the pharmaceutical industry, ASRS can store and retrieve temperature-sensitive products under controlled conditions. These systems can maintain specific temperatures and humidity levels to guarantee the integrity of medications. ASRS can also help manage strict regulatory compliance for storage and handling.

How much does an automated storage and retrieval system cost?

The cost can vary widely depending on the type, size, and customisation of the system. Depending on the system, prices can range from under $100,000 to several million dollars.

While upfront costs can be significant, long-term savings and efficiency gains can justify the cost.

What are the typical maintenance requirements for an automated storage and retrieval system?

Regular maintenance is paramount for the optimal performance of your automated storage and retrieval system, including mechanical inspections, software updates and troubleshooting, all of which require skilled technicians.

Can you customise an automated storage and retrieval system for your warehouse’s needs?

Yes, automated storage and retrieval systems can be highly customised to meet specific operational requirements, including the handling of unique product types or integration with specialised warehouse management software.