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.
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 this category. Such systems of this type are operated by automatic storage and retrieval cranes or shuttle Systems 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 warehouse and from this area to the order picking zone, to the production area or to the shipping department.
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, Göpfert, Hauff, Jeld Wen, Martin Bauer, Puma, Simba Dickie Group, Trolli
Pallet 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
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.
> Small footprint
The footprint of high-bay warehouses is significantly smaller than that of manual warehouses. Goods can be stored at heights of over 40 metres.
> High storage capacity
Due to the height of the building, the storage capacity per square metre is very high – ideal for large storage volumes.
> Low picking errors
Since the correct goods are automatically delivered to the person via conveyor technology and the picker is easily guided by the warehouse management software, picking errors are very rare.
> Higher throughput and speed
A pallet can be removed from the high-bay warehouse and delivered to the picker via conveyor technology in a short time. High-bay warehouses are fast, reliable and enable short delivery times.
> High cost-effectiveness with silo warehouses
With silo warehouses, there is no need to search for and design buildings. They can be erected in a short time and are particularly cost-effective from a height of approx. 20 metres. The roof and walls are fixed to the steel structure.
> High investment
The construction of a high-bay warehouse involves significantly higher investment costs than manual, forklift-operated warehouses.
> Complex construction
A high-bay warehouse has specific requirements in terms of construction, floor plate and fire protection.
> Maintenance costs
Regular maintenance is particularly important, as despite proven technology, a malfunction can lead to a standstill in the racking aisle.
> Higher planning and implementation costs
Only manufacturer-neutral logistics planning that shows which automation concept best suits the product range and order structure provides an accurate basis for decision-making.
> Less flexible
Automatic high-bay warehouses are difficult to expand or adapt.
The management of automated high-bay warehouses is a fundamental part of the Klinkhammer warehouse management software. It includes all functions to portray an automated warehouse. However, manual 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 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
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