What is an Automated Racking System?

As the volume and variety of goods in warehouses grow, traditional storage systems can become a challenge. Automated racking systems are an excellent solution that warehouses are turning to. These systems combine advanced robotics and software to bring more efficient storage to warehouses of all sizes. This article shares how automated racking systems work and why modern warehouses are turning to them. 

Automated Racking Systems Explained

An automated racking system is an automated storage and retrieval system (AS/RS) that uses technology to store and retrieve goods with minimal human involvement. Traditional racking systems rely on forklifts and manual labor, but automated racking uses robotics and software to simplify the process. 

This system typically includes four parts:

• Racks: Organized shelf-like structures that hold products and optimize storage space.
• Shuttles: Robots that move products in and out of racks. 
• Conveyors and Lifts: Automated equipment that transports products across the warehouse or between storage levels.
• Software: Coordinates the movement of products and tracks inventory changes in real-time. 

Automated racking systems handle various products, from small items to large pallets. These systems make storage more efficient and reduce manual labor in warehouses. 

How Automated Racking Systems Work

When products arrive at a warehouse, they are scanned and entered into the warehouse systems. This software then identifies an optimal storage location based on product factors like size, weight, and demand. Once in the rack, 4-way shuttles transport the products to their assigned areas in the racking system. 

When a product is needed for order fulfillment, the system identifies its location and sends a retrieval command to the shuttle. The shuttle retrieves the item and works with the rest of the system to deliver it to a pick station. This precise process reduces delays and potential errors. 

Benefits of Automated Racking Systems

Increased Storage Capacity

Automated racking systems are excellent at maximizing storage space. These systems are highly compact and utilize vertical space to store products more densely. These systems reduce the need for costly warehouse expansions or additional storage locations. 

Operational Efficiency

Warehouses handling large order volumes seek increased speed and precision. Automated racking systems meet this need by quickly storing and transporting products to their destination. Robots identify and retrieve products faster than human workers, shrinking order fulfillment time. Automated systems also minimize downtime since robots can operate continuously without experiencing fatigue. 

Cost Savings

Though automated systems are an initial investment, they bring long-term savings with an impressive ROI. Warehouses with automation no longer rely on manual labor for repetitive or dangerous tasks, saving money on labor and worker’s compensation cases. Automation also reduces human error in order fulfillment, reducing costs associated with returns or replacements. Plus, modern automation equipment operates with minimal energy consumption, lowering utility bills. 

Scalability for Future Growth

Automated racking systems are a flexible solution for businesses experiencing growth or changes in operations. Businesses can quickly expand storage capacity by adding more racks and shuttles with little disruptions. This allows warehouses to respond to increasing demands during peak seasons without needing a complete infrastructure overhaul. 

Improved Workplace Safety

Automated racking creates a safer workplace by reducing manual handling by human workers. Shuttles lift and transport heavy items in compact spaces without human intervention, decreasing the risk of injuries. This provides a safer work environment for employees and helps businesses save on insurance costs. 

Real-Time Inventory Tracking

Manual inventory tracking inevitably leads to errors and inaccuracies. Automated racking systems use real-time tracking features that track inventory in real-time. Sensors monitor inventory, and software records the data, providing warehouse managers with the information they need to make informed decisions. Accurate inventory helps businesses avoid stock issues like overstocking, stockouts, and misplaced items. 

Industries Using Automated Racking Systems

E-Commerce Warehousing

E-commerce warehouses are under significant pressure to fulfill orders quickly and accurately. The flexibility of automated racking systems helps manage the high volume and diversity of SKUs in e-commerce. These automated systems are also highly scalable and can be scaled up and down for seasonal spikes in demand. 

Retail Warehousing

Retail warehouses often encounter bulkier items or products with shorter shelf lives. Automated racking systems ensure accurate inventory to reduce waste and avoid stockouts. Retail stores also require frequent restocking, which automated racking can streamline with rapid retrieval. 

Cold Storage Warehousing

Cold storage facilities working with products like food and pharmaceuticals have unique challenges due to their controlled temperature environments. Automated racking helps minimize human exposure to extreme temperatures and maximize storage density in refrigerated zones. Shuttles also handle products carefully to avoid damaging perishable goods and keep them in optimal condition. Accurate inventory tracking and product mapping help warehouses meet strict compliance guidelines regarding safety and contamination. 

Manufacturing Warehouses

Manufacturing facilities support production lines through smooth material flow. Automated racking stores raw materials and delivers them to the production line as needed to reduce downtime. Quick access to materials as needed maintains efficiency and minimizes waste throughout the manufacturing process. 

Final Thoughts

Automated racking systems help warehouses of all kinds reduce costs and streamline operations. From e-commerce fulfillment to cold storage, racking systems have many applications that help businesses stay competitive. Whether you want to improve your storage capacity or future-proof operations, an automated racking system is a reliable choice. 

Ready to transform your warehouse? Contact Prime today to learn more about how an automated racking system can benefit your business.