Carousel storage system

A carousel storage system is an automated storage and retrieval system (AS/RS) based on the 'goods-to-person' principle. Rather than an employee walking to storage locations, storage bins or containers move directly to the picking station along a closed track. The name is derived from the rotating motion, which resembles a carousel.

Functional principle and designs

The system consists of a chain of storage bins (carriers) that are mechanically linked. As soon as a specific item is requested, an electric motor sets the entire chain in motion. There are two main designs:

• Horizontal carousels: The storage bins rotate on an oval track on the floor. This variant is particularly suitable for picking small to medium-sized parts at high speeds.
• Vertical carousels (paternoster): The bins rotate vertically, similar to a paternoster lift. This allows for the optimal use of room height and saves up to 60% of floor space.

Application in order picking

In modern logistics, carousel systems are often used as part of an integrated system to boost efficiency. The software controls the carousel, ensuring that it always selects the shortest path to the retrieval opening for fast access. While an employee removes an item, the system can position itself for the next pick. Optical displays (pick-to-light systems) often help workers to immediately identify the correct bin and quantity.

Economic benefits

Using a carousel system is particularly advantageous when handling a high volume of small parts. By eliminating walking distances, picking performance increases significantly. Furthermore, the system is usually modular and can be flexibly adapted to the existing warehouse structure. Another advantage is the ergonomic design: picking always takes place at a comfortable height for employees.