The Future of Warehouse Efficiency: A Look at AS/RS Technology in Intralogistics
By Cecile Dick-Calmes, Marketing Manager at Daifuku Intralogistics America
Since the introduction of Automated Storage and Retrieval Systems (AS/RS) in the 1960s, automation has played a critical role in reshaping warehouse and production environments. These systems have evolved from simple storage aids to highly complex and adaptable technologies capable of addressing a wide range of operational challenges from space optimization and temperature control to labor efficiency and inventory accuracy.
This article explores the foundational principles of AS/RS, the diverse system types in use today, and how these technologies contribute to more resilient, sustainable, and flexible supply chain operations.
Building for Longevity and Adaptability
One of the key success factors behind AS/RS adoption is the focus on long-term reliability. Some early installations have remained in continuous operation for decades, demonstrating how well-engineered systems, paired with consistent maintenance and thoughtful planning, can offer lasting value. In specialized environments like cold storage, where temperatures can reach as low as -40°C, early innovations enabled automated systems to replace manual operations under harsh conditions. These early developments laid the groundwork for today’s cold-capable AS/RS solutions, which are now commonly used in food, pharmaceutical, and industrial applications.
Why Tailored Solutions Matter
Not all warehouses are created equal, and neither are their automation needs. Across industries, organizations encounter a wide variety of product types, load dimensions, storage requirements, and operational workflows. Because of this, AS/RS systems are most effective when tailored to the specific context in which they’re deployed.
Factors such as facility layout, order volume, SKU diversity, and environmental conditions should inform system selection and design. A flexible, customized approach to automation ensures the solution delivers measurable impact not just on day one, but as operations evolve over time.
Types of AS/RS Systems in Use Today
AS/RS technologies come in several forms, each designed to meet different handling and throughput needs:
1. Unit Load AS/RS
• Typically used for larger, heavier items such as pallets or industrial components
• Capable of multi-depth storage and vertical installations exceeding 40 meters
• Suitable for high-density, high-throughput environments, including those with extreme temperature conditions
2. Shuttle-Based Systems
• Designed for handling cases, totes, and trays
• Support multi-format storage within a single aisle
• Modular and scalable, making them ideal for dynamic environments such as e-commerce and pharmaceutical distribution
• Effective in goods-to-person picking and order buffering applications
These systems can be configured to handle various load sizes, operational speeds, and temperature zones, allowing organizations to design environments that meet both current and future demands.
Applications Across Key Sectors
Cold Storage and Food Processing
In refrigerated environments, automation improves safety, reduces energy usage, and supports compliance by minimizing human exposure to extreme conditions. AS/RS systems help reduce door openings and maintain stable temperatures, both of which support product integrity and operational efficiency.
General Warehousing and Distribution
In high-throughput facilities such as third-party logistics centers, pharmaceutical warehouses, and retail fulfillment hubs AS/RS enables faster order picking, reduced labor costs, and improved inventory visibility.
These advantages are essential in today’s competitive, customer-driven supply chains.
Contributing to Sustainable Operations
Sustainability continues to be a driving force behind warehouse innovation. AS/RS technologies support environmental goals by:
• Reducing energy consumption through smart routing and regenerative braking
• Minimizing building footprints via vertical storage designs
• Improving inventory accuracy, reducing waste and overproduction
• Lowering emissions by reducing reliance on forklifts and manual transport equipment
By designing energy efficiency and operational precision, AS/RS systems align with both environmental and economic objectives.
Looking Ahead
As supply chains face increasing pressure to be faster, smarter, and more adaptable, automation will remain a key enabler of long-term success. Whether addressing labor shortages, maximizing space, or supporting omnichannel distribution, AS/RS technology continues to evolve to meet the needs of modern logistics.
Organizations considering AS/RS implementation should start with a clear understanding of their operational goals and challenges and engage cross-functional teams from engineering and IT to operations and leadership to ensure alignment throughout the automation journey.
