In today’s fast-paced supply chain and warehousing environments, maximizing space and efficiency is no longer optional—it’s essential. Traditional static storage methods like shelving and bins may appear cost-effective initially, but they come with hidden inefficiencies: wasted space, poor density, and limits on growth.
By comparing traditional shelving solutions to modern automated systems like horizontal carousels and Automated Storage and Retrieval Systems (AS/RS), you can make informed decisions to unlock productivity, space savings, and improved inventory control.
Traditional Shelving/Bins: Fast, Cheap, and Limited
Static shelving remains one of the most common storage solutions due to its simplicity and low upfront cost. However, it creates significant inefficiencies that can hamper growth:
- Wasted Aisle Space: More space is consumed by aisles than by actual storage.
- Low Storage Density: Shelf depth often goes unused, limiting capacity.
- Efficiency Barriers: Lack of adaptability to changing product sizes or storage needs reduces overall effectiveness.
Shelving Floor Space Analysis
Let’s examine a typical 7-foot shelving setup to highlight its limitations:
| Metric | Value |
| Total Sections | 212 (36” x 18” x 84”) |
| Floor Space Used | 2,484 square feet |
| Gross Capacity | 6,678 cubic feet |
| Net Storage Density | 0.94 cubic feet per square foot |
Takeaway: Traditional shelving systems fail to maximize the use of available floor space, offering minimal density and flexibility.
Shelving/Bins with Flow Racks: Still Unoptimized
Even when flow racks are added for better accessibility, fixed storage solutions often struggle with:
- Cube and Velocity Issues: Fixed storage locations are not optimized for product size (cube) or movement frequency (velocity).
- FIFO Challenges: Maintaining First In, First Out inventory processes requires manual effort.
- Reliance on Pickers: Inconsistent picking processes depend heavily on employee familiarity with storage layouts.
Horizontal Carousels: A Step Towards Automation
Horizontal carousels provide a modern, automated alternative to static shelving. By rotating carriers to the operator, carousels eliminate walking, reduce wait times, and maximize space efficiency.
Key Features:
- Welded wire carriers with adjustable shelves ranging from 12”–36” width and 10”–24” depth.
- Load capacities up to 1,500 lbs per carrier.
- Heights from 6 feet to 12 feet to match your facility’s requirements.
Carousel Pod Example
A typical carousel pod setup with two (30-bin) horizontal carousels demonstrates significant gains:
| Metric | Value |
| Gross Capacity | 2,880 cubic feet |
| Net Storage Density | 3.47 cubic feet per square foot |
| Space Utilization | 80% |
| Floor Footprint | 675 square feet (including workstation) |
Takeaway: Horizontal carousels significantly increase storage density and improve workflow efficiency by automating product retrieval.
Benefits of High-Density AS/RS
If you’re looking for the most advanced storage solutions, Automated Storage and Retrieval Systems (AS/RS) offer transformative benefits:
- Space Savings: AS/RS can reclaim up to 85% of your current storage footprint.
- Productivity Gains: Automated systems boost throughput by up to 400%.
- Picking Accuracy: Achieve near-perfect accuracy rates of 99.9%, minimizing errors.
- Inventory Control: Gain real-time visibility and control over inventory data.
- Improved Ergonomics: Automated systems reduce strain on workers, handling items safely and efficiently.
Visualization: Traditional vs. Automated Systems
Additional Applications: Unlocking Order Consolidation
Automation doesn’t stop at storage—systems like horizontal carousels and AS/RS can streamline order consolidation, improving staging and distribution processes:
- Order Staging: Consolidate and prepare orders faster for shipment.
- Improved Accuracy: Reduce errors through automated sorting and retrieval.
- Space Utilization: Free up valuable floor space for high-priority activities.
Why Choose PeakLogix for Your Storage Needs?
At PeakLogix, we specialize in designing and implementing customized storage solutions that help you:
✅ Maximize Space: Reduce wasted floor space and increase storage density.
✅ Boost Productivity: Automate processes to cut down on walking and waiting time.
✅ Enhance Accuracy: Achieve consistent, reliable results with automated systems.
✅ Improve Workflow: Tailor your storage solutions to fit your specific needs.
Ready to Transform Your Warehouse?
Static shelving may be holding you back, but automation can take your operations to the next level. PeakLogix is here to help you analyze, design, and implement smarter storage solutions that improve productivity, maximize space, and set you up for sustainable growth.
Contact us today or call us at 1-800-123-4567 to schedule a consultation.
