Automated High-Bay Warehouse

From multiple-deep channel storage system to silo.

Thanks to the compact design a high space utilization and storage density can be achieved by an automated high-bay warehouse. Our storage systems are available in various configurations and designs, from single-deep or multiple-deep Channel storage system to built-in shelving or silo.



Deep-freeze store

Central store

What is an automated high-bay warehouse?

Automated high-bay warehouses are used for the storage of packaged goods on pallets. In accordance with the industrial building directive, racking systems featuring a height of 7.50 m or more are classified as high-bay warehouse. Such high-bay warehouses are operated by automatic storage and retrieval cranes which get their transport orders from a warehouse management and material flow system. Complex control systems are responsible for controlling the machines (e.g. Step 7). Conveyors transport the goods to be stored to the high-bay warehouse and from this area to the order picking zone, to the production area or to the shipping department.

High-bay warehouse - For More Storage Capacity and Optimum Utilization of Space

The reasons for building a fully automated high-bay warehouse are saving floor space, expanding storage capacities, shortening the logistics chain and improving delivery quality. Intelligent, networked automation modules, from high-bay warehouse to the order picking zone, the production area or the shipping department take care of many time-consuming tasks, increasing the overall efficiency. Depending on your needs, we individually adapt the high-bay warehouse to your goods, the downstream and upstream systems and the required throughput such that you are able to benefit from a smooth and optimal performance.

References:   ACVK, AKF, Big, Denree, Denso, Frei, Jeld Wen, Lantmännen, Marburger, Puma, Schletter, Trolli

We are happy to advise you personally and without obligation

High-bay warehouse design types

Pallet high-bay warehouse
In accordance with the industrial building directive, racking systems featuring a height of 7.50 m or more are classified as high-bay warehouse. For this type of warehouse and due to the often heavy loads special profiles are used for the structural steelwork which are exactly designed and dimensioned to the required needs. Depending on the fire protection concept the planners allow for free spaces for sprinkler systems and piping. Alternatively, it is also possible to work according to the principle of oxygen reduction (inertization) in case an airproof building shell is used. Based on article range and order structure, the planners realize single, double or triple-deep high-bay warehouses to optimally address the requirements.

Channel storage system
In channel storage systems several loading units or pallets are stored consecutively in channels on special profiles. Stand-alone, cable-based or battery-powered shuttle vehicles, which are transported to the respective channels by means of an automatic storage and retrieval crane, store and retrieve the loading units in the high-bay warehouse. Compared to a conventional pallet high bay warehouse, the advantage of this type of warehouse is its better utilization of space. The channel storage system is an effective solution for storing large quantities of little article diversity.

Storage type - in line

  • Single-deep
  • Multiple-deep

Storage system with a gallery level
In the storage system with a gallery level, gangways for manual order picking are integrated into the high-bay warehouse's structural steelwork. Both operator sides of the rack rows, on which pallets are stored, are equipped with a falling protection or guardrail. Forklift trucks transport the pallets to the corresponding rack locations. Storage systems with a gallery level are often used in combination with station picking zones for slow moving articles (also called slow movers).

Silo storage
The constructional steelwork of the racking system represents the supporting substructure for roof and façade. Used in combination with storage and retrieval cranes, a silo storage system is considered as machine and thus benefits from short amortization periods. Using this design type for high-bay warehouses, it is possible to realize heights of more than 40 m. Further advantages are short assembly and installation times as no halls and buildings are required and low operational costs as storage space in great heights is opened up.

Built-in storage
Built-in storage systems are integrated into and individually adapted to existing buildings and halls. Existing space that has been used otherwise so far often offers an ideal link to production zone and shipping area. Built-in storage systems may be automated or operated with floor-borne vehicles. This type of high-bay warehouse offers the advantage of adding functional value to existing objects.

Klinkhammer - a general contractor also for the following topics:

Fire protection: Sprinkler systems,

oxygen reduction

Air conditioning

Roof and wall panelling

Warehouse vehicles in the high-bay warehouse

Narrow forklift truck

Rail-bound or curve-going storage and retrieval crane (AS/RS) or lifting beam

Channel vehicles (Muli)

Shuttle vehicles

Multi-level shuttle

Energy-saving technologies

Energy recovery

Intermediate circuit technology for immediate reuse of released energy

Power adaptations through driving strategies

Software for automated and manual high-bay warehouses

The management of high-bay warehouses is a fundamental part of the Klinkhammer warehouse management software. It includes all necessary functions to portray an automated high-bay warehouse. However, manual high-bay warehouses, e.g. narrow-aisle warehouses, are supported. Various pallet types and heights can be taken into account for storage, retrieval and relocation and be assigned to storage location types due to their compatibility. Control is ensured for different hardware such as AS/RS with single- or multiple loading handling devices,  several load handling devices, single- or multi-deep storage with telescopes or “Muli” satellite vehicles (channel stores). The storage topology as well can be configured almost indefinitely: single-deep, multiple-deep, combined storage locations (one load carrier spans across several width- or depth units). Often, also functional combinations such as flow channels for manual order picking can be found in a high-bay warehouse.

Based on parameterization and setup different storage and retrieval strategies can be applied. Hence, managing and monitoring field, traverse and compartment support loads is possible. The channels of a multi-deep storage can be mixed or may contain only load carries with the same article or batch. It is possible to trigger consolidation runs (reorganization) which compress the warehouse and create storage locations or totes belonging to one and the same order can be merged in advance in a staging area to speed up the picking/retrieval process according to the goods-to-man principle. 

The performance of the AS/RS is path-optimized by 

  • Distance-time calculation for optimum travelling between storage and retrieval actions
  • Weighting of the distance-time calculation by priority and age of a transport order
  • Checking for additional orders during travel in case of multiple load handling devices
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