Automated Storage and Retrieval Systems (AS/RS)

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Automated Storage and Retrieval Systems (AS/RS) create smarter, more efficient storage environments by maximizing vertical space and ensuring fast, accurate access to inventory. From stacker cranes handling full pallets to compact cube storage and mobile AS/RS, these systems manage growing volumes with greater precision, speed, and reliability.

Toyota Automated Logistics pairs proven technologies and deep engineering expertise to design AS/RS systems that fit your operational goals—whether you're increasing throughput, improving accuracy, or expanding capacity. We assess your product mix, inventory flow, and long-term needs to define the right architecture, delivering dependable performance at scale and seamless alignment with your automation roadmap.

Overview

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What it is: Systems that automatically store and retrieve inventory using cranes, shuttles, or robotic mechanisms within a defined storage structure like racking, shelves, or grid system.

Why it matters: AS/RS systems can increase storage density by up to 85% while achieving 99.9%+ inventory accuracy and throughput rates exceeding 1,000 transactions hourly.

How we help: Toyota Automated Logistics analyzes your product flow and facility layout to design and integrate an AS/RS solution tailored to your operation. We deliver high-performance systems that maximize storage density, accuracy, and throughput.

Capabilities

Flexible Product Handling

AS/RS systems manage a wide mix of load types from pallets and cases to totes and eaches, ensuring consistent, reliable storage across diverse product profiles.

High-Density Vertical Storage

AS/RS systems tap into vertical space that traditional racking cannot reach, dramatically increasing storage capacity without expanding your facility footprint.

Automated Inventory Control

Every movement is tracked in real time, maintaining continuous accuracy, eliminating manual counts, and providing full visibility through seamless WMS integration.

High-Throughput Order Handling

Optimized sequencing and double cycle handling keep storage and retrieval in constant motion, delivering fast, consistent order processing and smoother downstream workflows.

Goods-to-Person Picking

Mini-load, mobile AS/RS, and cube-based systems deliver items directly to ergonomic workstations, eliminating travel time and reducing operator strain for faster, more accurate picking.

Climate-Controlled Operation

AS/RS solutions operate dependably in ambient, refrigerated, and frozen environments, reducing energy loss and keeping workers out of extreme conditions.

Key Benefits

Maximize Storage Density

AS/RS increases storage capacity within the same footprint by utilizing vertical space and enabling multi-deep storage, while eliminating the wide aisles required for human or forklift access.

Achieve Near-Perfect Accuracy

Automated handling reduces errors, with most AS/RS installations achieving 99.9% or higher inventory accuracy.

Accelerate Throughput

Automated system coordination drives significantly higher throughput compared to manual operations and maintains performance during peak workloads

Reduce Labor Requirements

Goods-to-person systems and mobile AS/RS reduce picking labor while improving ergonomics, eliminating travel fatigue, and supporting stable execution even in tight labor markets. Pallet AS/RS drastically reduces manual rack travel, search and locating time, and inventory transaction time, decoupling throughput from labor availability.

Protect Inventory

Controlled, automated handling reduces product damage from drops, collisions, and improper storage conditions.

Applications

TAL provides a comprehensive evaluation to determine which AS/RS technologies deliver the best return. Our analysis focuses on inventory movement and projected demand to ensure the system is properly sized for long-term performance.

Automated Storage and Retrieval Systems are deployed across a wide range of industries:

Warehouse and Distribution
Manufacturing
Automotive, Aerospace and Heavy Industry
Food and Beverage
E-Commerce and Retail Fulfillment
Cold Storage and Temperature-Controlled Facilities

Frequently Asked Questions

How much floor space does AS/RS save compared to conventional storage?

AS/RS typically increases storage density by 40-85% within the same footprint. A facility that conventionally stores 10,000 pallets could increase capacity to 15,000–18,000 pallets with a unit load AS/RS. With cube-based AS/RS, a manual operation storing 25,000 cartons in roughly 60,000 sq ft could shrink its storage area to around 20,000 sq ft. The exact improvement depends on building height, product dimensions, and storage configuration.

Can AS/RS operate in freezer and cold storage environments?

Yes. AS/RS systems are engineered specifically for temperature-controlled environments, down to -30°F deep freeze applications. Automated operation reduces door openings, decreases refrigeration costs, and eliminates worker exposure to extreme cold.

How does AS/RS integrate with existing warehouse management systems?

AS/RS controls integrate with WMS platforms through standard interfaces and APIs. The Warehouse Control System receives instructions from your WMS and returns transaction confirmations in real time. TAL has integration experience with all major WMS platforms.

What is the difference between crane-based and shuttle-based AS/RS?

Crane-based systems typically use a single stacker crane per aisle, moving vertically and horizontally to access any location. Shuttle-based systems use multiple independent carriers operating on rails within the racking. Shuttle systems offer higher throughput and redundancy.

Can AS/RS handle mixed product sizes and weights?

Yes, within defined parameters. Mini-load systems handle varying tote and carton sizes within their design envelope. Unit load systems accommodate different pallet sizes and weights up to system maximums.

Smarter Storage for Peak Performance