Automated Storage & Retrieval Systems (ASRS)

AS/RS stands for Automated Storage and Retrieval System. It is a computer-controlled system that automatically places and retrieves loads from defined storage locations. AS/RS systems are typically used in warehouses and distribution centers to improve efficiency and accuracy of storage and retrieval operations.

Automated storage and retrieval systems (ASRS) transform inventory management for warehouses and distribution centres. They are computer-controlled systems that mechanically store and retrieve goods from pre-defined storage locations in a facility with speed, accuracy, and precision. They can be configured to pick individual items as well as cases and pallets in manufacturing, distribution, and warehouse operations.

AS/RS systems typically consist of the following components:

• Storage racks: The storage racks provide the physical space for storing the loads.
• Lift trucks: The lift trucks are used to move the loads within the storage racks.
• Control system: The control system manages the operation of the AS/RS system.

Types of ASRS

There are two main types of AS/RS systems: unit-load and mini-load. Unit-load AS/RS systems are used to handle large, heavy loads such as pallets or cases. Mini-load AS/RS systems are used to handle smaller, lighter loads such as individual items or cartons.

There are 8 ASRS technologies which can be broken down into three major categories:

• Shelf based picking - an entire shelf or tray of product is delivered to an operator.
• Bin based picking - an individual bin or tote of product is delivered to the operator.
• Robotic picking - robots are used to deliver products to an operator.

Shelf and Tray Picking ASRS Technologies:

1) Vertical Carousel Modules

Vertical Carousel Modules are a series of carriers attached in fixed locations to a chain drive. Movement is powered by a motor, which sends the carriers in a vertical loop around a track in both forward and reverse directions.

2) Horizontal Carousel Modules

The horizontal carousel modules comprise highly dense storage bins with shelves that are supported by an oval track. The bins rotate bi-directionally via the shortest path. The shelves are easily adjustable to resize changing inventory.

3) Vertical Lift Modules (VLMs)

A vertical automated storage and retrieval system (AS/RS) is comprised of trays in the front and back and an inserter/extractor system that runs down the centre. The VLM inserter/extractor automatically locates stored trays and retrieves trays from both the front and back of the unit with a push of a button and delivers them to the operator at a pick window.

Bin and Tote Delivery ASRS Technologies

4) Crane-Based Mini-Load AS/RS

A mini load AS/RS system is an automated carton or tote storage solution designed for smaller (or mini) load handling that stores, tracks, picks and delivers cartons or totes without human interaction.

5) Vertical Buffer Modules (VBMs)

VBMs function as mini-load systems for storing, picking, and buffering small parts. Essentially, the enclosed system houses bins and trays that are retrieved by an automated crane that delivers the products to a pick station. Such systems are designed to both automate picking and maximize vertical storage in a building.

Robotic Delivery ASRS Technologies

6) Robotic Shuttle Systems

Robotic Shuttle Systems are autonomous vehicle used in place of traditional forklift trucks to handle pallets in rack areas. They minimize the need for forklifts to enter lanes, reducing congestion and enabling warehouses to maximize every square inch of floor space.

7) Cube Automated Storage & Retrieval System (CASRS)

Cube automated storage and retrieval systems or hive systems are densely packed automated tote storage systems. It is the is the newest type of ASRS technology using a fleet of robots to drive across tracks on top of the grid and they are synchronised to move bins out of the system and deliver to an operator port.

8) Floor Robots (AGVs/AMRs)

Autonomous mobile robots (AMRs) are robotic vehicles, smaller than AGVs, that operate without the need for human control or intervention. AMRs typically move dynamically around any obstacles they encounter.  

AS/RS systems offer a number of benefits, including:

• Increased efficiency: AS/RS systems can significantly reduce the time and labor required to store and retrieve loads.
• Improved accuracy: AS/RS systems can help to ensure that loads are stored and retrieved accurately.
• Increased safety: AS/RS systems can help to reduce the risk of accidents, injuries, and damage to products.
• Increased flexibility: AS/RS systems can be easily adapted to changes in product volume or storage requirements.

The cost of an AS/RS system can vary depending on the size and complexity of the system. However, the benefits of AS/RS systems can often outweigh the costs.

Here are some examples of industries that use AS/RS systems:

• Manufacturing
• Distribution
• Retail
• Healthcare
• Food and beverage
• Logistics

If you are considering implementing an AS/RS system, there are a number of factors you will need to consider, including:

• The size and complexity of your warehouse or distribution center
• The volume of products you need to store and retrieve
• The accuracy requirements for your storage and retrieval operations
• Your budget

Once you have considered these factors, you can start to evaluate different AS/RS systems and providers. There are a number of reputable AS/RS providers available, so you should be able to find a system that meets your needs and budget.