Automated Storage and Retrieval Systems

An Automated Storage and Retrieval System (ASRS or AS/RS) is an advanced solution that uses computer-controlled and robotic technologies to automate the storage, retrieval, and management of goods within a defined racking structure. Designed to optimize space and enhance operational efficiency, ASRS systems are widely used in modern warehousing and distribution environments.

At its core, an ASRS integrates structural racking, precision robotics, and warehouse software such as a Warehouse Execution System (WES). These components work together to place and retrieve items with minimal human intervention. The system is capable of handling both standard and nonstandard load types, storing them in predefined locations with uniform accuracy.

ASRS is especially beneficial in environments where storage density is critical, such as facilities with limited floor space or the need for vertical expansion. It performs exceptionally well in high-volume operations where large quantities of goods are frequently moved into and out of storage. Since ASRS systems are designed specifically for storage and transportation without additional processing, their structure emphasizes speed, accuracy, and operational consistency.

By automating repetitive tasks and reducing reliance on manual labor, ASRS not only increases inventory accuracy but also minimizes damage risks associated with human error. This makes it ideal for industries where product value is high, handling costs are sensitive, or fulfillment accuracy is paramount.

For example, in a manufacturing warehouse using an automated shuttle racking system, raw materials such as metal parts or electrical components are stored in standardized bins placed on uniform pallets. Each bin is barcoded and tracked in the warehouse management system. When a production line requests a specific part, the shuttle robot retrieves the exact bin without needing to search the entire storage area. This not only speeds up the picking process but also simplifies inventory audits, as checks can focus on individual bins instead of the entire stockroom. 

ASRS storage racks automate the movement of goods, saving retrieval time

• Material: ASRS racks are made of steel.
• Load Capacity: 1500 kg per pallet.
• Dimensions: Dependent on the warehouse area.
• Mobility: Cranes can operate up to 18 meters in height, with rail lengths of the system reaching up to 75m.
• Robot Speed: Eurorack Shuttle transports at a speed of 35m/minute with load and 65m/minute without load.
• Operating Voltage: 380VAC.
• Control Software: Eurorack ASRS Controller.
• Control Signal: Mesh Wifi.
• Transfers: Utilizes a combination of the following equipment: roller conveyors, chain conveyors, and pallet direction-changing conveyors.
• Management Marking: 1D, 2D code, RFID.

E-commerce effectively applies the 18m high ASRS warehouse racking system

Full Automation with Sensor-Based Retrieval

The Eurorack ASRS Racking System offers a comprehensive solution for businesses seeking speed, precision, and maximum warehouse performance. Built on advanced sensor-based retrieval principles, the system fully automates the entire process of receiving and dispatching goods. This eliminates manual handling, greatly accelerates cycle times, and positions ASRS as a superior alternative to traditional warehousing methods.

Maximum Space Utilization

One of the most important advantages of the Eurorack ASRS is its ability to maximize available space. Because it operates without the need for multiple aisles, the system achieves an extremely high storage density. The compact, centralized racking design makes it especially valuable for warehouses with space limitations or vertical expansion needs.

High-Capacity Storage for Diverse SKUs

The system is capable of managing and storing a wide variety of SKU codes, even across warehouse footprints exceeding 10,000 square meters. It supports high-bay storage with exceptional efficiency, making it ideal for industries with large and diverse inventories.

Real-Time Inventory Monitoring and Control

Inventory control is another strong point. Eurorack ASRS integrates advanced warehouse management software that enables automated monitoring, area-specific access control, and detailed user permission settings. This results in reduced overstock, increased inventory turnover, and complete visibility into stock movements.

Significant Labor Reduction

Labor costs are significantly reduced—by up to 75 percent—thanks to full automation from the inbound point to outbound flow. Processes such as sorting, storing, and transferring goods are performed without human intervention, helping businesses operate more efficiently while cutting down on operational costs.

Flexible Design and Configuration Options

In addition, the Eurorack ASRS offers flexible configuration options to fit different warehouse needs. From varying structural dimensions to integrated conveyor belt systems, every component is engineered for compatibility and seamless material flow across distinct operational zones.

Fast and Accurate Item Retrieval

The system ensures high selectivity, enabling quick, timely, and accurate product retrieval. Operators can access required items without delay, which improves response time and service reliability.

Forklift-Free Operation and Workflow Integration

Another advantage lies in its adaptability. ASRS cranes can retrieve goods directly from racks without the need for forklifts and deliver them to designated packaging or dispatch areas. This smooth transition between storage and handling stages enhances workflow and safety.

Large-Scale Storage with Full Accessibility

With large-scale storage capability and one hundred percent access to all stored items, the Eurorack ASRS Racking System is a robust, intelligent solution for modern warehouses aiming to scale operations, reduce costs, and maintain complete control over inventory.

What Industries Can Benefit Most from Eurorack’s ASRS System?

The Eurorack ASRS racking system is designed to meet the high-performance demands of modern supply chains across a wide range of industries. With its precision, speed, and storage efficiency, ASRS is particularly well-suited to sectors that require strict inventory control, high throughput, and space optimization. Key industries that benefit most from Eurorack’s ASRS solutions include:

Cold Storage and Food & Beverage

ASRS systems thrive in temperature-controlled environments where minimizing human exposure is critical. Eurorack ASRS ensures efficient pallet handling in freezing conditions, while preserving product integrity, meeting food safety regulations, and maximizing the use of expensive refrigerated space.

Pharmaceuticals and Medical Supplies

In industries where traceability and accuracy are non-negotiable, ASRS offers real-time inventory tracking, batch control, and secure access. Eurorack's high-density, sterile-compatible systems help ensure compliance with strict industry regulations.

E-Commerce and Retail Distribution

The fast-paced nature of online and retail fulfillment demands speed, selectivity, and inventory visibility. Eurorack ASRS enables fast picking, handles a wide range of SKUs, and scales effortlessly to accommodate seasonal demand spikes without adding warehouse labor.

Manufacturing and Industrial Production

Manufacturers rely on just-in-time delivery of raw materials and components. ASRS helps ensure continuous material flow to the production line, reduces downtime, and provides efficient storage of parts, tools, and finished goods—all while maximizing space in production-adjacent areas.

Automotive and Heavy Equipment

Eurorack ASRS handles bulky, high-value components with ease, enabling precise placement, secure storage, and damage-free retrieval. Ideal for managing large SKUs and keeping critical parts readily available in service or assembly operations.

Logistics and 3PL Providers

Third-party logistics companies must balance speed, accuracy, and adaptability. Eurorack’s scalable ASRS systems offer high throughput, multi-client inventory handling, and seamless WMS integration, making them a smart choice for logistics hubs and shared distribution centers.

ASRS is an automated storage solution that helps enterprises optimize warehouse space, increase inbound and outbound speed, improve inventory accuracy, and significantly reduce labor costs. With a flexible design, stable operation, and long term scalability, ASRS is well suited for manufacturing warehouses, logistics centers, e commerce fulfillment, and cold storage facilities. Contact Eurorack today to receive on site assessment and practical consultation tailored to your warehouse operations.

 

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The ASRS racking system is composed of the following parts:

1. Inventory Retrieval Robot

For the ASRS racking line, the Eurorack Robot Shuttle is utilized for rotating goods in and out of the racking system. Capable of carrying up to 1500 kg per pallet and moving at speeds of up to 35m per minute. Additionally, the Eurorack Pallet Shuttle ASRS can operate in 3 dimensions: single-direction retrieval, bi-directional retrieval, and tri-directional retrieval. Thus, it helps to optimize operational time efficiently.

2. Pallet Conveyor System 

This is a system set up extending from the warehouse entrance into the interior. Its function is to automatically transport goods without the need for manual labor. Moreover, in the goods sorting phase, such as labeling, tagging, batch numbering, etc., a mini robot performs these tasks.

3. Crane for Stacking Goods 

To support the import and export of goods, cranes are set up in the aisles of the system, either fixed or mobile depending on the storage area. They are responsible for lifting, sorting, and placing goods in high storage locations and vice versa.

4. Storage Racking System

Robust steel racks that make the most of warehouse height up to 40m and have an outstanding load capacity of over 50,000 kg per system. The types of racks commonly used in ASRS warehouses are Mobile Racks and Shuttle Rack, which offer superior storage capacity and are well-suited for warehouse automation.

5. Robot Management Software

Software that manages all processes from storage, preservation to distribution of goods according to the timeline updated by the system.

6. Control Box 

Through Wifi or radio waves, it transmits control commands to the retrieval robot.

Eurorack Shuttle Robot is an important part integrated in the ASRS system

• Based on the principle of sensor retrieval, the entire process of goods dispatch and receipt is completely automated. The dispatch and receipt speed of ASRS is a superior choice over other warehouses.
• Maximizes space: does not require many aisles, the centralized system improves the density of stored goods.
• Allows storage of multiple SKU codes over 10,000m2: the system provides high-efficiency high-bay storage.
• Minimizes inventory: automated management software, area authorization, and user groups ensure safety, increase circulation, and strictly monitor inventory.
• Reduces labor by 75%: from the assembly point to the goods circulation area, everything occurs automatically, manual labor is reduced, and businesses save a significant amount on labor costs.
• Offers multiple model options: specially designed in various sizes, conveyor belts facilitate goods circulation from receipt to preset positions, compatible with specific warehouse spaces.
• High selectivity: timely, quick, and accurate retrieval.
• High improvement capability: forklifts are not needed as ASRS cranes can directly retrieve goods from the warehouse, then continue to move to the packaging area.
• ASRS Automated Storage Retrieval System stores on a large scale, allowing 100% access.

Operation of ASRS Racking Systems

ASRS is a storage rack system constructed from various systems to create an automated operation process. Goods are marked with barcodes or IDs for easy inventory control and accurate classification. Below are the operating principles of the ASRS racking system:

When a pallet containing goods is brought into the warehouse entrance, the ASRS system begins to activate to manage all data about the shipment (via barcodes or IDs displayed on the package). Then, the software analyzes and accounts for the data to assign the storage location of the goods, based on parameters such as weight, size, and area.

At the same time, warehouse managers can also use positioning software like IOT, RTLS to monitor and track the location of the pallets within a certain area. Thus, when dispatching goods, the work is done quickly.

How the ASRS system works

What type of warehouse should use ASRS racks?

The intelligent automated ASRS racking system is relatively suitable for warehouses with a large volume of goods, whether homogeneous or heterogeneous, and requires continuous retrieval. The system has the ability to classify correctly according to models and production batches, and it is also combined with various intelligent machines such as robotic stackers, gantry cranes for loading and unloading, along with a conveyor system optimally distributed for the convenience of goods movement. Therefore, if you are in the FMCG, electronic appliances, furniture, etc., sectors, the ASRS system is compatible for best application.

Automated Storage and Retrieval Systems (ASRS) are widely implemented across manufacturing and distribution environments to streamline material handling, optimize space, and reduce labor demands. These systems are capable of managing everything from small parts and work-in-process (WIP) items to large tools and specialized equipment. Below are common use cases where ASRS technology delivers high impact:

• High-Density Storage: eASRS provides compact, vertically optimized storage for components and raw materials used in production processes. This helps facilities save valuable floor space while improving accessibility.
• Fast and Accurate Order Picking: By automatically delivering requested items directly to the operator, ASRS speeds up the picking process and reduces walking time. Integrated software systems ensure accuracy in item selection and streamline fulfillment workflows.
• Kitting and Pre-Assembly Staging: ASRS supports the kitting process by grouping specific components required for assembly. Kits are securely stored and retrieved just-in-time for production, improving assembly line efficiency and reducing bottlenecks.
• Order Consolidation: The system can temporarily store partially fulfilled orders, keeping them organized and secure while awaiting remaining items. This ensures faster final dispatch and better control over outbound logistics.
• Inventory Buffering: ASRS units serve as dynamic buffer zones to hold inventory temporarily between production steps or during scheduling gaps. This keeps operations balanced without overloading production lines.
• Storage of Work-in-Process Items: Sub-assemblies and WIP materials can be stored safely within the system until needed, reducing clutter around the production floor and improving organization.
• Secure Storage of Tools, Dies, and Molds: For heavy or high-value tooling, ASRS offers ergonomic, secure storage solutions. It protects sensitive assets and ensures safe retrieval without manual lifting.
• Maintenance and Spare Parts Management: ASRS provides a reliable and space-saving way to store spare parts and maintenance materials onsite, helping maintenance teams reduce downtime and respond quickly to technical issues.
• Returns and Replenishment Handling: Returned goods and inventory awaiting replenishment can be managed efficiently through ASRS. It helps sort, store, and reintegrate items back into active stock with minimal manual handling.
• Use in Controlled Environments: ASRS is well-suited for climate-sensitive applications such as cold storage, clean rooms, and dry environments. The sealed design and precision operation help maintain strict environmental standards.

Choosing ASRS racking from Eurorack means more than just adopting an automated storage solution — it’s a strategic investment in performance, reliability, and long-term growth. With nearly 15 years of experience in the storage industry, Eurorack has earned the trust of global leaders such as Nestlé, Pepsico, and DKSH.

What sets Eurorack apart is not only its commitment to engineering excellence, but also its ability to deliver projects on schedule with exceptional attention to after-sales service. From consultation to completion, every project is managed with the highest standards of professionalism, ensuring customer satisfaction at every stage.

By partnering with Eurorack, you’re not just upgrading your warehouse — you’re empowering your business with a future-ready system, backed by a manufacturer that prioritizes your success and adapts to your evolving needs.

If your business is ready to embrace ASRS automation and move toward smarter warehousing, contact Eurorack today — and take the first step toward a more efficient, scalable, and intelligent storage solution.