High-Density Automated Storage and Retrieval Systems | Westfalia

Smart Storage Solutions

Transform Your Warehouse with Our AS/RS

In today’s fast-paced logistics environment, efficient storage and retrieval are critical for success. Our Automated Storage and Retrieval Systems (AS/RS or ASRS) offer innovative solutions to maximize space, increase efficiency, and improve accuracy in your warehouse operations.

Using a data-driven approach, we ensure our AS/RS solutions are tailored to meet your specific needs.

Discover AS/RS Design

Automated Warehouse at Martin's Bakery from Westfalia Technologies showing racking and single-mast ASRS Automated Storage

Backed by decades of expertise and innovative Satellite® technology, Westfalia’s AS/RS solutions ensure consistent performance and minimal downtime. With over 400 installations globally, our experience drives successful outcomes. Our designs of equipment, controls, and software are continually refined with a focus on standardization to ensure long-term support.

Maximize pallet storage capacity by utilizing vertical and horizontal space with precision. Westfalia’s AS/RS stores pallets from 1 to 18 deep per aisle to provide a high-density storage system that dramatically reduces warehouse footprint and delivers substantial cost savings through optimized space utilization.

Westfalia’s AS/RS handles various pallet types and adapts to specific warehouse layouts and operational requirements. It scales easily with your business, accommodating diverse inventory needs and ensuring flexibility and customization.

Our AS/RS solutions ensure smooth, accurate load movements, eliminate deflection and prevent inventory damage. This feature improves system performance and extends operational longevity by providing precise pallet support.

Savanna.NET® Warehouse Execution System (WES) offers real-time inventory tracking, advanced analytics, and seamless integration with the AS/RS. It optimizes material flow and coordinates tasks across subsystems, providing complete control over your operations.

What Sets Our Solutions Apart

Benefits of Westfalia’s AS/RS Solutions

Optimize Performance and Efficiency for Modern Warehouses

Our AS/RS integrates seamlessly with our advanced warehouse systems, enabling a unified process that eliminates the need for manual intervention. By manufacturing most equipment and developing all software and control systems in-house, we maintain superior quality, control, and reliability.

This vertically integrated approach reduces risks and ensures unmatched quality, leading to cost-effective and timely solutions that are fully supported now and into the future. Our systems can handle a wide variety of products and storage requirements, providing the following benefits:

Unmatched Stability and Reliability

Triple-Rail System for Warehouses

Our support system enhances stability, load-bearing capacity, and adaptability for various pallet types and storage requirements. This AS/RS design is a key factor in reducing system faults, leading to more reliable operations.

Multiple Pallet Types: Handles various pallet types including standard GMA, CHEP, 9-block, most plastic pallets, and many custom pallets.
Damage Protection: Eliminates pallet deflection to prevent damage to pallets and inventory.
Balanced Movements: Ensures even movement to eliminate product tipping and damage, enhancing system performance.
Fault Reduction: By protecting pallets from undue stresses like deflection, the system minimizes faults and decreases the need for manual intervention.

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Core Technology

Key Components of Westfalia’s AS/RS

Westfalia’s AS/RS solutions are built on advanced technologies and designed for optimal performance and flexibility in various warehouse configurations.

Efficient Automated Movement

Storage/Retrieval Machine (S/RM)

Our S/RM enables efficient horizontal and vertical positioning movement within your AS/RS, providing versatility across many applications regardless of depth, height, or width constraints.

Single Mast Design: Ideal for lighter loads and more compact systems, supporting heights up to 40 feet.
Double Mast Design: Provides added stability for heavier loads and higher speeds, supporting heights up to 140 feet.
High Speed: Achieves horizontal speeds of up to 900 ft./min and vertical speeds of 400 ft./min.
Load Capacity: Capable of handling loads up to 2 x 3,500 lbs for dual-load machines, and up to 5,000 lbs for single-load machines.

Optimal Pallet Handling

Satellite® Pallet Handling Device

Westfalia’s Satellite® Rack Entry Vehicle delivers quick, safe, and versatile pallet handling, outperforming traditional rack entry vehicles that lift the load. The design includes a center third rail for proper pallet support and can handle one or two pallets at a time in your AS/RS.

By keeping control technology outside the machine in a climate-controlled environment, reliability is significantly enhanced. This approach eliminates processors, I/O blocks, power supplies, drive technology, and positioning technology within the machine, making the equipment more dependable and easier to maintain.

Quick and Safe Movement: Utilizes a counter-rotation principle for fast and safe pallet handling.
High Throughput: Processes up to 120 pallets per hour per S/RM.
High-Density Storage: Stores pallets up to 18 deep, maximizing your warehouse space.
Adaptability: Can be lengthened or shortened to accommodate non-standard unit loads and designed to handle one or two pallets at a time.

Westfalia's Satellite pallet handling device demonstrating different configurations for safe and quick movement within ASRS

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Savanna.NET® WES

Our Savanna.NET® Warehouse Execution System (WES) serves as the central hub for optimized inventory management and order fulfillment in your warehouse. Seamlessly integrating with conveyors, picking systems, palletizing equipment, and more.

Centralized Control: Manages all aspects of inventory management and order fulfillment from a unified platform.
Seamless Coordination: Coordinates effectively with conveyors, picking systems, palletizing equipment, and more.
Operational Optimization: Enhances efficiency and accuracy through real-time data analytics and process automation.

Explore our Software

Savanna.NET Warehouse Execution System WES showing close up of firefly monitoring and real time inventory management

Streamlined Material Flow

Conveying Systems

Our systems ensure efficient, continuous, and accurate movement of goods within the AS/RS, enabling seamless operations across diverse warehousing configurations.

Seamless Integration: Works in harmony with S/RMs and other devices commonly used in automated systems such as stretch-wrappers, label applicators, stackers, dispensers, staging systems, etc.
Precision Control: Provides real-time monitoring and precise control for reliable product movement throughout the warehouse.
High Throughput: Engineered to handle large volumes, meeting the demands of rigorous order fulfillment schedules.
Durability and Reliability: Built with robust components for continuous operation and minimal maintenance.

Seamless Coordination

Integrated Systems for Maximum Efficiency

Our AS/RS integrates seamlessly with our automated picking systems and Savanna.NET® Warehouse Execution System (WES), creating a cohesive and efficient warehouse solution. This integration ensures that your operations, whether manual or automated, are synchronized for optimal performance, minimizing complexity and maximizing throughput.

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Frequently Asked Questions About Automated Storage and Retrieval Systems

Automated Storage/Retrieval Systems (AS/RS’s) automatically store and retrieve loads from defined storage locations using automated, software controlled robotic equipment, such as storage/retrieval machines, shuttles, robots, and conveying systems. They are often integrated into a complete order fulfillment solution to facilitate the delivery of goods through a variety of distribution channels. At the heart of Westfalia’s AS/RS is a rack entry vehicle (Satellite®) that can store and retrieve loads in a compact, space efficient way. Peripheral automation to pick orders, transport loads, stage, and prepare loads for shipment are used to augment an AS/RS to facilitate a complete, end-to-end solution.

Westfalia is one of the few AS/RS providers that designs and manufactures almost all equipment, controls, and software in-house. This vertically integrated approach ensures product standardization, support, and responsibility for resolving any problems encountered with a system during its life. Proprietary technology such as triple support of all pallets ensure that these systems operate at the highest levels of reliability demanded in high-stress, production environments.

Storage lane depths are dependent on data metrics and are designed to maximize storage utilization and throughput (they can vary from 1 deep to about 18 deep). Both of these concepts (storage utilization and throughput) often compete with one another, which is why it is so important to be aware of the risks and use proper design methodologies.

With Westfalia’s triple rail pallet support, most pallet types can be considered (CHEP, GMA, plastic, etc), no matter how they are designed. By ensuring the proper width of the lane and supporting the structural elements such as pallet stringers or blocks, the pallet is under no stress when stored in the rack. This leads to more reliability and less problems related to pallet quality.