Views: 0 Author: Site Editor Publish Time: 2026-08-26 Origin: Site
· High labor costs
Manual storage and retrieval operations require large workforces, with labor costs rising year over year.
· Insufficient storage capacity
Traditional flat warehouses utilize only 30-40% of available vertical space, limiting storage density.
· Low throughput efficiency
Manual handling creates bottlenecks during peak periods, restricting inbound/outbound throughput.
· Inventory inaccuracy
Manual recording leads to stock discrepancies, affecting production scheduling and order fulfillment.
· Safety risks
Forklift operations in narrow aisles increase accident probability and product damage rates.
The ASRS solution integrates the following subsystems into a cohesive automated warehouse:
· High-Precision Rack Structure
Cold-formed steel rack system engineered via finite element analysis (FEA), supporting loads up to 6,500 kg per unit, with heights reaching 34 meters.
· Stacker Crane / Shuttle System
Rail-guided stacker cranes with operating speeds up to 240 m/min, or four-way shuttle systems for multi-depth storage, enabling continuous operation up to 23.5 hours per day.
· Conveyor & RGV System
Roller/belt conveyors and rail-guided vehicles for automated inbound/outbound goods transport, with sorting rates exceeding 1,200 items per hour.
· WMS/WCS Software
Warehouse Management System and Warehouse Control System for real-time inventory tracking, task allocation, and equipment scheduling, achieving inventory accuracy of 99.9%+.
· Electrical Control System
PLC-based control architecture with safety interlocks, barcode/RFID identification, and seamless ERP/MES integration.
· Space Utilization
By optimizing the ratio of vertical storage height to footprint, space utilization can exceed 80%-far surpassing the 30-40% typical of conventional flat warehouses.
· Throughput Efficiency
Hourly inbound and outbound operational efficiency is 3-5 times higher than manual operations, significantly reducing order processing times.
· Inventory Accuracy
Leveraging WMS and real-time tracking via barcode or RFID, inventory accuracy remains consistently above 99.9%, virtually eliminating errors and omissions.
· Labor Reduction
Replacing manual handling with automated storage and retrieval reduces warehouse staffing requirements by over 60%, effectively alleviating labor shortages.
· Operational Hours
The system supports up to 23.5 hours of continuous daily operation, enabling near 24/7 functionality.
· Storage Capacity
Single-project pallet capacity can exceed 110,000 positions (e.g., the China Resources Beverage project), meeting large-scale storage demands.
· ROI Period
Through labor savings and increased productivity, the return on investment (ROI) for medium-to-large projects typically ranges from 3 to 5 years, offering significant economic value.
· Food & Beverage
Raw material storage, finished goods warehousing, cold chain integration
· Pharmaceutical
GMP-compliant storage with full traceability and temperature control
· Automotive
Parts distribution centers, JIT line-side supply, work-in-process buffer
· Electronics & Electrical
Component storage with ESD protection, high-SKU management
· New Energy
Battery materials, electrode storage, hazardous goods management
· Third-Party Logistics (3PL)
Multi-client warehousing with flexible allocation
· Cold Chain
Cold storage ASRS with low-temperature shuttles and insulated structures
Stacker Cranes (single/double column, turning type)
Four-Way Shuttles (hydraulic, mechanical, cold-storage versions)
Conveyor Systems (roller, belt, chain)
WMS / WCS Software
High-Precision ASRS Rack Structures
Shuttle-based ASRS with a design capacity of 110,000+ pallet positions, integrating WMS/WCS for real-time inventory management. The system enables high-density storage for beverage products while maintaining FIFO compliance and rapid order fulfillment.
Stacker crane ASRS with maximum running speed of 240 m/min, supporting continuous operation of 23.5 hours per day. The system handles high-frequency component retrieval for electronics manufacturing with 99.9%+ inventory accuracy.
ASRS project with a vertical construction height of 34 meters - the tallest single-unit intelligent warehouse in its industry segment - maximizing land utilization for lighting product storage.
Q: What information is required for ASRS layout design?
A: Warehouse dimensions (length, width, clear height), pallet size and weight, number of SKUs, daily inbound/outbound volume, storage strategy (FIFO/LIFO/batch), and any integration requirements with existing WMS/ERP/MES systems.
Q: Can the ASRS connect with our existing WMS or ERP?
A: Yes. SUNLI's WCS supports standard interfaces (API, XML, database-level) for seamless integration with mainstream WMS, ERP, and MES platforms, enabling real-time data synchronization.
Q: What is the typical project timeline from design to commissioning?
A: For a standard ASRS project, the timeline is approximately 4-8 months depending on system complexity, site conditions, and customization scope - covering planning, manufacturing, installation, commissioning, and acceptance testing.
Q: What after-sales support is provided?
A: SUNLI offers 24/7 remote support, on-site maintenance, spare parts supply, software upgrades, and system optimization throughout the system lifecycle.
