As warehousing and logistics operations evolve, the pressure to increase accuracy, maximize space, and reduce labor costs continues to grow. One proven way to meet these challenges is by implementing Automated Storage and Retrieval Systems (ASRS)—technologies designed to streamline how materials are stored, picked, and managed.
There are many types of ASRS, but they generally fall into two categories based on the size and type of items they handle: Unit-Load and Mini-Load systems. Below, we break down the most common AS/RS solutions under each category to help you determine which is best suited to your operation.
Unit-Load ASRS
Built to handle large, palletized loads. Ideal for high-volume warehouses and bulk inventory operations.
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Unit-Load Cranes
Stacker cranes transport pallets to and from high-density storage racks, providing reliable and efficient access to heavy loads.
Applications:
- Distribution centers
- Cold storage
- Manufacturing facilities
Benefits:
- Maximizes vertical space
- Reduces forklift dependency
- Efficient handling of large volumes
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Unit-Load Shuttle Systems
Horizontal shuttles move pallets across deep-lane storage, often paired with vertical lifts for higher throughput and storage density.
Applications:
- Food & beverage warehousing
- High-volume storage environments
- Multi-deep pallet storage
Benefits:
- Fast access to pallet loads
- Modular and scalable
- Ideal for deep-lane applications
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Mobile ASRS for Pallet Loads
Mobile ASRS solutions use autonomous mobile robots (AMRs) or guided vehicles (AGVs) to transport palletized goods between storage and workstations—without fixed infrastructure.
Applications:
- Dynamic or changing layouts
- Multi-zone fulfillment operations
- Facilities with varied inventory profiles
Benefits:
- Highly flexible and reconfigurable
- Lower upfront infrastructure investment
- Scales easily with operational growth
- Reduces manual transport labor
Mini-Load ASRS
Engineered for smaller items like totes, cartons, and bins. Perfect for high-SKU, high-pick-rate environments.
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Mini-Load Cranes
Smaller-scale cranes for retrieving bins or totes in tight racking systems, ideal for high-density storage of small parts.
Applications:
- E-commerce fulfillment
- Parts warehouses
- Assembly and kitting
Benefits:
- High-speed retrieval
- Great space optimization
- Supports dense SKU storage
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Shuttle-Based Systems (Totes/Cartons)
Automated shuttles travel between shelf levels to move totes or bins to picking stations in high-throughput operations.
Applications:
- Apparel and electronics
- Pharmaceutical distribution
- Omnichannel fulfillment
Benefits:
- Rapid, scalable picking
- Space-saving layout
- Easily adapts to SKU growth
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Vertical Lift Modules (VLMs)
Enclosed towers that store items vertically and deliver them to a user at an ergonomic access point.
Applications:
- Maintenance, repair, and operations parts storage
- Healthcare supplies
- Secure inventory areas
Benefits:
- Maximizes vertical height
- Increases picking accuracy
- Controlled inventory access
Each type of AS/RS serves a specific purpose and can drastically improve how your operation handles inventory, picking, and storage. Whether you’re looking to improve throughput, save floor space, or reduce labor costs, there’s an AS/RS solution that fits.
Not sure which system is right for your facility? Contact our team to discuss your unique operational needs and explore the best-fit AS/RS solution for your business.
