Automated Storage and Retrieval Systems (ASRS) have rewritten traditional warehousing operations by blending digital, robotic and racking elements to create better storage solutions.
What sets them apart from traditional manual picking systems is their unmatched accuracy and productivity. But with a dizzying array of ASRS types on offer, selecting the right automated system can be challenging.
Enter top-loading ASRS - a crowd favourite due to its unique space-saving features, particularly when paired with a mezzanine floor system. In this guide, we will dive into everything you need to know about top-loading ASRS and how you can use them to optimise your business.
What is a Top-loading ASRS?
A top-loading ASRS is a type of automated storage and retrieval system designed to handle high-density storage by utilising the vertical space of a warehouse. This system typically includes components such as inventory bins, retrieval robots and a sophisticated inventory management system for warehouse operations.
The primary function of automatic storage and retrieval systems is to automate the process of storing and retrieving goods, by virtue of which you can improve efficiencies and reduce manual labour costs.
Components of a Top-loading ASRS
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AutoStore Grid: The structural framework that holds the inventory bins in place, allowing robots to navigate and retrieve items.
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Inventory bins: Containers used to store products within the grid.
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Retrieval robots: Automated machines that move along the grid to pick and place inventory bins.
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Inventory management system for warehouse: The software that controls the entire ASRS, ensuring precise and efficient operations.
Top Benefits of Automatic Storage and Retrieval Systems
By implementing a top-loading ASRS in your warehouse, you can reap a number of benefits:
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Improved Storage Density: Top-loading ASRS systems maximise storage density by utilising vertical space effectively. This is particularly beneficial for warehouses with limited floor space, as it allows for more products to be stored in a smaller footprint.
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Increase in Eficiency and Productivity: with automated storage systems in warehouses, the process of retrieving and storing goods is significantly faster and more accurate. Robots can operate continuously without breaks, leading to higher throughput and reduced error rates.
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Better Inventory Management: An advanced inventory stock management system integrated with top-loading ASRS ensures real-time tracking of inventory levels, reducing the risk of stockouts and overstock situations. This enhances overall inventory management and planning.
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Minimised Manual Labour Expenses: By automating repetitive and physically demanding tasks, top-loading ASRS reduces the need for manual labour. This not only cuts labour costs but also minimises the risk of workplace injuries, leading to a safer working environment.
How does a Top-loading ASRS Function?
Automated Storage and Retrieval Systems (ASRS) are versatile solutions used to manage various types of inventory, from small parts and sub-assemblies to maintenance parts and large tools.
Top-loading ASRS systems are commonly found in manufacturing and distribution facilities and serve multiple purposes. The operation of a top-loading ASRS involves several steps, all controlled by a central warehouse management system (WMS), including the following:
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Storage: Products are placed into inventory bins, which are then stored in the autostore grid. The WMS ensures that frequently accessed items are stored in easily accessible locations.
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Retrieval: When an item is needed, the WMS sends a signal to the retrieval robot. The robot navigates the grid to locate the specific bin and brings it to the picking station.
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Picking: At the picking station, workers or additional automation systems pick the required items from the bin. The bin is then returned to its original location or a new one, as directed by the WMS.
AutoStore Grid
The AutoStore™ Grid is a versatile and scalable robotic storage and picking solution that integrates five essential components: robots, a storage grid, ports, bins and a controller cabinet. In this system, robots move within the grid to swiftly deliver bins to various AutoStore workstations or ports for efficient inventory management and restocking.
To accommodate different throughput requirements, the system includes seven distinct ports. The controllers oversee operations, while analytics continuously optimise performance. By adapting to your customer’s demands, the AutoStore Grid ensures your supply chain remains agile and ready.
Why pair ASRS with Mezzanine flooring?
As Australia’s leading manufacturer and supplier of mezzanine solutions, here at Unistor we actively advocate the pairing of mezzanine floors with ASRS for optimal warehouse efficiency - for several good reasons:
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Capitalised Overhead Space: Mezzanine floors provide additional levels of storage space, which can be seamlessly integrated with top-loading ASRS. This combination allows for the full utilisation of vertical space, further increasing storage density.
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Fine Tuned Workflow: By incorporating industrial mezzanine floors, warehouses can create designated zones for different activities such as picking, packing, and sorting. This improves workflow efficiency and reduces congestion in high-traffic areas.
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Scalability and Flexibility: Mezzanine floors offer a scalable solution that can grow with your business. As your inventory needs expand, additional levels can be added to accommodate more products without the need for significant changes to the existing warehouse structure.
Partner with Unistor for Warehouse Excellence
Top-loading ASRS systems are the future of warehousing - and the future is now. Offering increased storage density, boosted efficiency and unmatched inventory management, these systems can cut costs, heighten customer satisfaction and improve your bottom line.
Partner with Unistor if you are seeking top-notch automated warehousing solutions to elevate your operations. With over thirty years of industry expertise and partnering with leading ASRS providers like AutoStore and Ocado, Unistor is the one-stop-shop for warehouses looking to embrace automation - offering end-to-end project services to help you plan and implement a top-loading ASRS.
Our in-house team of warehouse storage solution experts partner with automation integration partners in assessing the needs of your facility and logistical challenges, before we design custom mezzanine floors and coordinate with our network of experienced, dedicated ASRS providers, ensuring easy integration with minimal downtime.
Our skilled installation team ensures that mezzanine floors meet all safety and regulatory standards - providing ongoing support and maintenance to keep your system running smoothly.
Ready to optimise your warehouse operations with ASRS? Take the first step and get in touch with the Unistor team today.
