Mini Load AS/RS Systems
A mini load AS/RS system, or automated storage and retrieval system, is an automated carton or tote storage solution that stores, tracks, picks and delivers cartons or totes without human interaction other than dropping off and picking up. A mini load system is a crane-based system.
If you’re looking for an AS/RS system for pallet storage and retrieval, visit our unit load system page. For companies that handle both pallets and cartons, a combination of a unit load and a mini load system is a viable option.
REB Storage Systems International is a material handling systems integrator that provides full project management of mini load AS/RS systems. Our services include design, permitting support, subcontractor management, procurement of materials, and installation.
Read below to learn more about REB’s mini load AS/RS systems.
How Mini Load AS/RS Systems Work
In most cases, cartons are transported to and from the system by a forklift. The forklift either drops the case off at the required aisle (meaning multiple possible drop off points) or at an automated induction system (meaning one drop off point for all cartons), which then takes the carton to the correct aisle.
Here are the steps taken in this system:
- The system scans the carton to verify it’s the correct weight, size, and not leaning or falling apart.
- A forklift truck or an automated induction system brings the carton to the correct aisle.
- It then places the carton on a conveyor located on the ground level. The crane then retrieves the carton from the conveyor, transports it to the correct level of the system, and places it into the correct position.
- Unloading works the same way: the crane retrieves the carton from the system and transports it to the ground level at the receiving location. Pick up the carton with either a forklift or an automated induction system and transport it to the needed location.
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REB’s Turnkey Services for Mini Load AS/RS Systems
REB provides full project management of your mini load AS/RS system. A REB project manager will be your point of contact throughout the project. Our project managers prioritize communication and will make sure that all applicable parties have a firm understanding of timelines and progression of the project.
Read below to better understand our mini load AS/RS system project management services.
Design Services
The first step in REB's design services is to speak with your REB account executive so that we thoroughly understand the scope of your project. If necessary, we’ll conduct an onsite assessment. We want to make sure we understand your goals and current pain points so that we provide you with a solution that is optimized to your operation.
During the design process, we’ll obtain information such as your SKU profiles, space restrictions, and picking processes. We’ll work with you to ensure that your mini load AS/RS system is set up to suit your requirements. For example, if you require your system to have a first-in, first-out or a last-in, first-out product flow.
Once all information is obtained, REB project designers will create a CADD drawing of your mini load AS/RS system that suits all space and picking process requirements.
Permitting Support
If necessary, we’ll evaluate if permitting for your mini load AS/RS system is required through our permitting support services. If permits are required, we’ll put together and submit all drawings and other documentation needed for permit approval. This often includes a high pile storage report.
Subcontractor Management
Once your mini load AS/RS system design is finalized, your REB project manager will secure all suppliers and subcontractors. We’ll manage their involvement through the project. This includes freight and installation.
Our project management services prioritize communication and will make sure that all applicable parties have a firm understanding of timelines and progression of the project.
System Installation
REB Storage Systems has more than 60 years of professional experience installing material handling systems in warehouses nationwide. We’ll ensure that your operation’s mini load AS/RS system is safely installed and compliant with MHI & OSHA standards while it optimizes your storage space and improves efficiency.
Is a Mini-Load AS/RS System Right For Your Operation?
A mini load AS/RS system is ideal for a large array of operational features. Some of these include:
High number of SKUs, low number of cartons per SKU: A system can accommodate up to 3 pallets deep. Since each lane should be designated to one SKU, generally a low number of pallets of each SKU works best with a crane-based system.
Availability to store higher than 30 ft.: since a standard forklift’s reach is about 30 ft., this often limits the height of a traditional rack system, resulting in wasted storage space. An AS/RS system will be able to utilize the entire available height of your DC.
Stores products that require date code management or scan verification: This is often found with pharmaceuticals, medical supplies, and food distributors.
Stores heavy loads: mini load systems are able to handle very heavy loads, up to 6,000 lbs. This can be an ideal solution vs. having forklift equipment or other types of equipment placing and retrieving heavy loads within the system.
Freezer storage: AS/RS systems allow for the entire area of a freezer to be utilized, which is expensive real estate.
Have multiple DCs that could benefit from being consolidated into one: if you’re considering consolidating your DCs into one, an AS/RS system may be right for you. Consolidating DCs will cut down on costs overtime, since you’re not paying for extra real estate, employees, etc. Sounds like a no-brainer, right? But, there are challenges that many DCs face when considering this.
Many companies don’t feel they can consolidate since it will mean higher throughput requirements for the one DC vs. multiple. A mini load system will allow for the higher throughput needed.
Lack of availability of consistent warehouse labor: one benefit of implementing a mini load system is it can cut down on labor costs. Less manpower is needed, since the system does much of the work. If you find yourself consistently taking time to hire and train new warehouse staff, a mini load AS/RS system may be an ideal alternative.
Advantages of Mini Load AS/RS Systems
Labor reduction: less manpower is needed in an AS/RS system. Employees are no longer needed to travel great distances to store and load cartons. Cartons can be shipped just in time resulting in faster turnaround times. Additionally, systems can be placed right in front of dock doors for quick unloading and loading of trucks. These systems can also replenish picking areas.
Increased pick accuracy: systems can reach 99.95% pick accuracy or greater.
Utilizing full building height: since a standard forklift’s reach is about 30 ft., this often limits the height of a traditional pallet rack system. This results in wasted storage space. A mini load system will be able to utilize the entire available height of your DC.
Ability to handle higher storage and throughput counts: if you want to achieve higher throughput, a mini load AS/RS system is ideal. This ability to handle higher storage and throughput counts is another reason that this type of system allows companies to consolidate products in multiple DCs into one.
Reduces damage to products and the system: an AS/RS system eliminates product-to-product contact, which reduces the likelihood of product damage. Additionally, since a forklift operator does not have to retrieve pallets from within the system, damage to the storage structure is eliminated.
Your Next Step for a Mini Load AS/RS System
Whether your next step is to gather more information or request a quote, consider REB Storage Systems. REB is a highly experienced systems integrator, in business since 1962. REB has 17 in-house project managers and project designers, all highly experienced in the material handling industry. These people know this industry inside and out.
REB is highly knowledgeable and experienced in designing and installing automation and racking solutions. We will make sure your system is the best fit for your SKU profiles and space. We work with you to provide a turnkey system. From design, products procurement, subcontractor management, install, and permitting support, REB handles it all for you.
We’d appreciate the opportunity to help you further, whether that be more information or a quote. Fill in the contact form on this page or call us at (800) 252-5955 to get in touch with a REB representative.