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Interlake Mecalux Automated Storage & Retrieval Systems AS/RS

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Revolutionize Your Warehousing Efficiency

Are you ready to transform your warehouse operations, increase productivity, and save valuable floor space? Look no further than Interlake Mecalux's Automated Storage & Retrieval Systems (AS/RS). Our cutting-edge technology is designed to streamline your logistics, optimize inventory management, and enhance the overall performance of your business.

 

Automated Storage & Retrieval Systems (AS/RS) represent a transformative leap in the world of warehouse and inventory management. These advanced technologies are designed to automate the storage and retrieval of goods, optimizing operational efficiency and accuracy while dramatically reducing labor costs. AS/RS systems are particularly invaluable in today's fast-paced and competitive business landscape, where speed, precision, and resource optimization are paramount.

 

At the heart of AS/RS are sophisticated robotics, conveyors, and computer-controlled software that work in harmony to handle tasks that were once manually intensive. These systems can efficiently and methodically transport products to and from designated storage locations, eliminating human error and drastically reducing the time needed to fulfill orders or access inventory. AS/RS solutions come in various forms, including unit load systems for large items, mini load systems for small parts, and pallet shuttle systems for palletized goods. Their flexibility and scalability make them suitable for a wide range of industries, from e-commerce and manufacturing to pharmaceuticals and logistics. By maximizing storage space, minimizing handling time, and ensuring impeccable inventory accuracy, AS/RS systems not only enhance a company's competitiveness but also pave the way for future growth and adaptability in a rapidly evolving market.

Why Choose Our AS/RS Solution?

1. Unmatched Expertise

With over 50 years of experience in the industry, Interlake Mecalux is a trusted global leader in AS/RS solutions. Our team of experts is dedicated to delivering customized, state-of-the-art automation systems tailored to your unique needs.

 

2. Maximizing Efficiency

Our AS/RS solutions are engineered to maximize your warehouse's efficiency. By automating the storage and retrieval of products, you'll reduce human error, minimize handling time, and boost overall productivity.

 

3. Space Optimization

Space is a valuable asset in any warehouse. Our AS/RS systems are designed to make the most of your available space by utilizing vertical storage and minimizing aisles, allowing you to store more in less space.

 

4. Enhanced Accuracy

Say goodbye to picking errors and inventory discrepancies. Interlake Mecalux AS/RS systems provide pinpoint accuracy, ensuring that the right products are always in the right place at the right time.

 

5. Scalability

Our solutions are scalable to accommodate your business's growth. Whether you need to expand your storage capacity or adjust to changing demands, our AS/RS systems can adapt to your needs seamlessly.

 

Custom Design

Every project is custom designed to fit your needs and budget

Installation

Professional installation

Warranty

Best in-class customer service and warranty

Our Process

Our pallet racking systems deliver unbeatable quality, flexibility and affordability. When you choose The Safety Source for your pallet racking project, we guarantee a product that you get:

 

Faster. Our manufacturers have a large inventory of standard components means we can quote, manufacture and ship your order faster.

 

Leaner. We partner with ultra-efficient manufacturers whose production process keeps our costs low. Lower cost to us means lower cost to you.

 

Better. Our partners are family-owned and operated for over 100 years, which means a refined pre-engineered system that offers the best quality and reliability.

3 Simple Steps

Design Consultation

Design Consultation

Receive an initial call within 24 hours. We'll assess your needs and visions.

Accurate Estimation

Accurate Estimation

Receive your quote in 48 hours. We ensure speed and accuracy.

Secure Installation

Secure Installation

Schedule an installation date as soon as you’re ready. We guarantee the dates we plan with you.

Automated Storage & Retrieval System Options

Pallet Shuttle

The Pallet Shuttle is a high-density storage system where a shuttle, powered by an electric motor, runs along rails inside a storage channel. By replacing forklifts, this radio shuttle solution considerably reduces operating times and enables SKUs to be grouped by channels rather than by entire lanes.

 

The shuttle follows orders sent by an operator through a WiFi connected tablet. It deposits its load in the first free location in the channel, while compacting the pallets as much as possible. Not having forklift traffic inside the lanes increases storage capacity in terms of depth and decreases the risk of accidents. Damage to the shuttle racks is then negligible, operator movements are optimized and warehouse operations modernized and made more flexible.

Technology Applied At Top Operating Speeds

Save space

-Store more pallets deep, since channels can stand more than 131 ft high. The maximum verticality is determined by the handling equipment used.

-The system works with minimal clearances between levels, which permits high-density storage.

-Built-in sensors on the shuttles help position loads intelligently, eliminating empty spaces in the storage lanes. As a result, the effective capacity of the warehouse (which considers goods flowing in and out of the warehouse) reflects its physical capacity.

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Save time

-Loading and unloading times are reduced, since the operator does not have to move around inside the lanes.

-The shuttle can travel at speeds of 295 ft/min when empty, or 148 ft/min when loaded.

-Load lifting cycle of just 2 seconds.

-With just a single command, the shuttle can progressively fill or empty a whole lane.

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Increased productivity

-More goods flowing in and out of the warehouse.

  • -Unlike standard drive-in systems, items can be grouped by channels, rather than requiring a full lane. Greater product diversification is the result.
  • -Optimization of operator movements through the product-to-person system, i.e., the load that moves to the operator.
  • -While the Pallet Shuttle carries out a command, the operator collects another pallet, achieving continuous workflows.
  • -Depending on temperature and load conditions, the shuttle can operate up to 10 hours, working at full performance.
  • -The easy-access lithium batteries have fast connections, makeing them cable-free. So, battery units can be changed quickly without interrupting the operational cycle.
  • -Elimination of errors.
  • -The shuttle rack system is easy to use and maintain.
  • -A single tablet can control up to 18 shuttles.
  • -Inventory function means the shuttle counts how many pallets are stored in a channel.
  • Cost savings

These benefits, combined with its efficient energy use, lead to immediate cost savings, making the Pallet Shuttle one of the most cost-effective compact storage systems around.

 

Versatility

-The shuttle has built-in sensors that enable different types of pallets to be detected and handled.

-The 4048 and 4840 Pallet Shuttle models work with different pallet sizes and widths. For example, the 4048 model can handle 40 inch deep pallets (and around 48 inch front ways). The 4840 model can handle 48 inch deep GMA pallets.

-All shuttles can operate in LIFO or FIFO mode. The operator simply selects the mode they wish to work with from the tablet.

-The shuttle platform is designed to carry pallets that have a 1 inch max. buckling limit.

-Any type of forklift can be used to handle the shuttle.

-Handle up to 3,307 lbs per pallet.

-Install the Easy WMS Interlake Mecalux Warehouse Management System Easy WMS on any compatible operator tablet.

-As a scalable system, it is easy to increase the number of shuttles in operation to match increasing productivity needs.

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Safety

  • -Thanks to the way that the structure is built, and given that forklifts do not need to drive into the shuttle racks, the risk of accidents is practically non-existent. The metallic bays are not damaged, thus maintenance is kept to a minimum.
  • -A user management feature prevents unauthorized personnel from operating the shuttles.
  • -Both the racking and the shuttles have built-in safety features specifically designed to ensure the Pallet Shuttle system operates correctly: rail end stops, pallet centralizers, position sensors, etc.

For quick, repeatitive in and out pallet transfers

By definition, a shuttle is a fast means of transport that travels between two fixed points at frequent intervals. Mecalux’s Pallet Shuttle fits this description precisely. However, its journey starts at the front of the racks up to the first available space in the storage channel, and back again (vice versa operation to unload).

 

Eventually, the evolution of compact storage systems raised important questions. Such as, why not use a motorized shuttle to handle pallets, instead of a forklift that drives into the storage channel? Why not use technology to increase loading and unloading speeds and optimize the effective capacity of a warehouse?

 

The smart choice was the Pallet Shuttle. Adapted rack structures mean an electric run shuttle can move inside storage lanes along a track, following the commands given by the operator using a WiFi control tablet.

 

The forklift simply leaves the load on the tracks, and the Pallet Shuttle picks it up and moves it autonomously. Pallets are kept as compact as possible, while each pallet is slotted in its location. Since forklifts do not need to drive into the lanes, handling times are lower, storage capacity is higher and deeper. Additionally, damage to the metal shelves is negligible, operator movements are streamlined and in-warehouse operations moderized.

 

In other words, the Pallet Shuttle system offers a compact storage solution that reduces operating costs and improves supply chain performance. Intelligent warehousing at its best.

Compact semi-automated warehouse with Pallet Shuttle

In semi-automated installations, operators only run the forklifts that carry the pallets and also activate the motorized shuttle. Otherwise, the movement of the shuttles inside the racking is automated.

Step 1

 

A forklift places the Pallet Shuttle into the channel where work is to be done.

Step 2

Next, the forklift is used to position pallets one by one in the channel entrance, resting them on the load-bearing beams.

Step 3

Using the tablet, the operator sends a command to the shuttle to start the loading operation. Once the pallet's location has been identified, the Radio Shuttle lifts the pallet slightly upward. It then moves horizontally until it reaches the first available location, where it deposits the pallet. Different sensors accurately control the movement of the load being stored.

Step 4

The Pallet Shuttle returns to the front of the lane to repeat the operation with the next pallet, and so on, as many times as needed until the channel is full. Before the front position is filled, the shuttle is removed from the lane and the sequence repeated in the next channel where work is required.

Load management systems

The semi-automated system allows for two types of operation:

LIFO (Last In, First Out)

Where the last pallet loaded is the first to be unloaded. Loading and unloading is carried out from the same aisle. It is the most commonly used solution with the Pallet Shuttle system.

FIFO (First In, First Out)

Where the first pallet loaded is the first to be unloaded. Two access aisles are needed, i.e. one to load the goods and another to unload them. As a FIFO or a storage by batch system, it is recommended for completely loading or unloading a level.

The forklift operator sends the storage and retrieval orders to the shuttle through a WiFi linked tablet. Operation it is very simple and user-friendly, not requiring any special training. Exceptional control functions include:

Pallet Selector

Select the type of pallet to be handled.

LIFO/FIFO Configuration

Select the load management strategy.

Change Work Aisle

Select which side of the structure you want to work on (i.e. FIFO mode).

Locking System

Activate the additional locking system, which increases contact between the Pallet Shuttle and the forklift's forks.

Space Savings

Group pallets at the beginning (LIFO) or end (FIFO) of the channel.

Continuous Loading/Unloading

Loads or unloads a channel without stopping.

Partial Unloading

Select the number of pallets to be extracted.

Inventory

Count the number of pallets stored in the channel.

Location Signal

Activate the acoustic and light signals to identify the selected shuttle's location.

User Management

Manage shuttle user permissions for authorized personnel.

Operating Mode Selector

Automatic or manual (for maintenance tasks).

Shuttle Indicator

Shows the number of shuttles in operation and their statuses.

Tiltmeter

Detect if the shuttle is incorrectly positioned in a channel.

Rescue

Recover a damaged shuttle from inside the channel.

Position Camera (Optional)

Facilitate the Pallet Shuttle's insertion on the rails.

Automation is within reach

In general, the Pallet Shuttle noticeably increases warehouse productivity when working with incoming and outgoing goods with many pallets per item.

 

So, it is a top pick for:

  • -Companies with few items and a large number of pallets..
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  • -Companies with massive loading and unloading activity.
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  • -Cold storage systems are highly-suited to warehouses where products need low temperatures, since storage volumes are fully used and handling times reduced. Installing an AS/RS makes the system even more efficient, through stacker cranes and shuttles.
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  • -Buffers for picked orders or temporary storage.
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  • -Seasonal product warehouses, where inflows and outflows depend on the season. So, goods accumulate over a period until a deadline when all must be released en masse, for example, ice cream or toys.
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  • -Warehouses that already use a high-density system and need to access a greater number of SKUs, store more pallets deep, or increase the number of incoming and outgoing movements, all with the aim of increasing productivity.

Mobile Racks

Optimize space by eliminating individual access aisles.

 

This system uses mobile bases to enable access to several shelves from one single working aisle. Ideal for refrigerated or deepfreeze storage.

The mobile pallet racking units are installed over guided bases that slide laterally, eliminating the need for multiple fixed aisles. With Movirack mobile racking and shelving, the aisles open up only when the operator requests access.

 

The motorized mobile bases are electronically-powered and are guided by rails in the floor.

 

Advantages

  • -Remote and computer-controlled storage
  • -Direct access to any pallet
  • -Efficient use of space
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The Movirack units are installed on mobile bases, opening up an aisle provides direct access to the desired pallet.

 

Utilization of available space is based on to two basic premises: increasing the storage capacity and reducing the storage area required.

Direct Access To Any Pallet In Storage

Since these shelving units are installed over bases, merely by opening up the corresponding aisle provides direct access to the desired pallet.

 

Makes The Most Of Available Space

This is possible due to two basic premises: increase storage capacity and reduction of storage area to build.

The Movirack system has multiple applications which can be accomplished using either Interlake or Mecalux rack.

Palletized Product Storage

 

-General Storage

-Product with average or low-level rotation

-Refrigerated storerooms

-Intermediary or shopping warehouses

Warehouse With Cantilever Shelves

 

-For sheets, reels, and large or irregular-sized products

 

In this case, the same use as for palletized products is applied

 

Conventional forklifts can be used (counterweighted or reach trucks) or specific for long products (lateral load or four-pronged fork lifts).

Refrigerated Storerooms

 

The Movirack system is ideal for low or medium-height refrigerated and freezer storerooms.

 

-Every pallet can be directly accessed

-Greater energy savings to generate cold air, since the air is distributed overa larger number of pallets in storage. The expense per pallet is reduced.

-There is better air circulation in down times when using the parking option, which increases the separation between shelves to spread the aisle space more equidistantly.

-With the parking option, if enogh space is available, aisles can be used to pick individual items from the lower shelves.

-The use of conventional forklift allows for direct access from the dock area to different points on the shelving unit.

Pallet Conveyor Systems

Fully automated product manipulation. High performance. Wide range of elements and applications.

 

Standardized and low cost conveyors make them accessible for any warehouse or factory where there is a need to join different work stations.

Technology Applied At Top Operating Speeds

Set of elements designed for transporting, accumulating and/or distributing goods to specific positions required by the logistics operations. This conveyor system represents an ideal combination between the efficiency of the stacker cranes and the entry, dispatch and handling processes of the load units.

 

  • -Wide range of devices for conveying load units.
  • -Standardization of measurements and components, as far as possible, with the aim of facilitating production, assembly and the future start-up of facilities.
  • -Reduction in delivery times and installation costs.

Pallet Stacker/Unstacker

The Pallet Stacker/Unstacker automates the process of stacking and unstacking empty pallets. Pallet stackers replace manual handling of pallets in automated material handling systems. Pallet stackers do the work for you, placing used pallets in a stack for reuse or transport. The pallet stacker receives single pallets from the in-feed conveyor and stacks the pallet with its heavy duty hoist system. Once stacked, the pallet stacker can then re-destribute the pallets to the desired location.

Pallet Check Unit (PCU)

The Pallet Check Unit will automatically approve or reject pallets based on designated parameters. The PCU can check for broken pallets, improperly stacked pallets, and even overweight pallets. When a pallet is rejected, it will be sent back so the issue(s) with the pallet can be addressed. Pallets that are approved will continue down the rollers to the next step of the shipping process.

Turntable Conveyor

When your plant layout requires a directional change in the smallest possible space of your conveyor system, you should consider using a Turntable Conveyor. The turntable conveyor can be used for product sortation, accumulation as well as directional changes.

 

Turntable conveyors are characterized by their ability to turn even heavy goods weighing several tons and thus change the direction of transport. The suitable conveying element (e.g. roller, strand or belt conveyor) is placed on the turntable or integrated. Turntable conveyors do not require a lot of space, they can be set up in the tightest of spaces. Where necessary, a full enclosure guarantees safe turning. A simple operation by handle is possible for manual revolving platforms, but a motor-driven version can also be realized.

Cross Transfer With Rollers And Chains

Chain Transfer

The chain cross transfer module is intended for heavy pallets. These units can handle many sizes and weights of pallets whether loaded or empty. They have been offered for unit loads up to 3,000 pounds. Heavy duty stops, rockers and other modules are available for such service.

 

Roller Transfer

The live bed is raised and lowered pneumatically into operating position to allow automatic in-feed or discharge of the work piece pallet at any point along the length of the transporter line. The powered rollers are wired to a terminal strip, and are controlled collectively as one drive motor.

Pallet Lift

Vertical conveyors are a more sophisticated version of the pallet lift and are used in automated storage and retrieval systems. Driven by an electric motor — just like a goods lift ― vertical conveyors are present in warehouses with conveyor systems, such as automated storage and retrieval systems. In this case, they can serve to connect different conveyor line levels, raise a pallet for another machine to pick it up and deposit it on a rack, automate truck loading and unloading, etc.

 

Vertical conveyors for pallets streamline vertical transportation in facilities with various connected levels. This automated solution does away with the need for operators to move the load manually using handling equipment, cutting down on warehouse travel and transportation times.

 

In fact, this vertical transport system can be combined with other automated solutions, such as pallet conveyor systems and even pallet checkpoints with the goal of maximizing productivity in the facility

The Safety Source Way

The Safety Source is the leading pallet racking installation service. We have hundreds of customers, from warehouses to distribution centers. If you are in need of pallet racking, we’ll be able to successfully complete the job within a reasonable timeframe.

 

Our team of pallet racking installers are experts and have many years of experience to hone their craft. As such, we can provide your business with a design consultation and quote within 3-5 business days.

If you choose to move forward with our proposal, with modifications or not, we will work you into our schedule on a mutually agreed-upon date. One of our project managers will stay in constant contact before, during, and after the installation to ensure you have complete satisfaction.

 

Call us today for any pallet racking you need for your business.  

 

For other similar services, like mezzanines check out our other industrial projects.

 

If you are looking for adaptable, multi-purpose storage, Interlake Mecalux pallet racking should be your first order of business. It provides the versatility you need, through the materials you trust. The Interlake Mecalux Selective Pallet Racking system provides an efficient use of floor space, load flexibility and easy reprofiling, all made possible through its extensive range of frame pieces and accessory components. Optimize your warehouse and get direct, continuous access to your inventory.

 

Roll-formed pallet racks are the most popular, functional racking in the industry. As the best solution for warehouse systems with palletized products, they store a wide variety of goods.

 

Advantages

-Direct access to each pallet

-Simple stock management

-Adaptable to any product volume, weight or size

-Cost savings through wide span beams with piston lock connectors

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Interlake Mecalux pallet racking comes with either bolted or boltless (welded) frames. The company's patented beam-to-frame connection creates the most rigid, reliable structure available. In addition, it provides exceptional protection against damage, tampering, as well as accidental beam disengagement.

We only use high-strength steel, certified to meet the strictest specifications. All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards. Baked enamel finishes and a durable powder coating ensure a long service life of rack systems, even under the most demanding industrial conditions.

 

Pallet rack shelving can be configured for a variety of uses and product sizes. One option is double-depth racks, which increase storage capacity by enabling four pallets to be stacked back-to-back (requires a deep-reach truck). Our heavy-duty pallet rack can also be used in the construction of rack supported buildings, as well as for more basic storage needs in any warehouse installation. Combine them with hand-stack shelves for best results.

Services We Provide

Safety Source is here to help your business expand and optimize its floorspace; here are some of the services we provide:

Single Depth Pallet Racking

Double Depth Pallet Racking

Pallet Racking With Underpass

Front Of Rack

Narrow Aisle Guiding System

Tall Pallet Racking Applications

Pallet Rack Components

  • There are a lot of different way you can customize your pallet racking system to fit your needs. When purchasing new pallet racking, it's best to consult one of our pallet racking experts, but here is a list of the common components of a pallet racking system to help get you started.
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  • Upright: Vertical beams that form the walls of the pallet rack; holes or slots are designed to interface with the load beam.
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  • Beams: Horizontal beams that form the shelves of the pallet rack.
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  • Pallet Supports: Situated between the load beams to support pallets.
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  • Wire Deck: Safety measure to prevent pallets or products on pallets from falling through the rack structure. Used for storing smaller products like boxes.
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  • Footplates: Also known as base-plates they are located at the base of columns and serve as anchors providing more stability for the rack.
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  • Shims: Are used when the uprights are going to be located on floors that might be uneven.
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  • Row spacers: Are in most cases used when bays (uprights) are arranged in back-to-back rows.
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  • Wall ties: May be used for further support if the uprights are arranged in a row along a wall.
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  • Column protectors: Also known as post protectors, are protective shields that can be installed around the base of an upright to minimize damage in areas where forklifts might hit the upright.
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  • Guard rails: Are installed to increase protection where forklifts might hit the upright.

Success Stories

The team at The Safety Source sat down and looked at our current space and provided an out of the box solution - a two story mezzanine with a inplant office installed on the 2nd floor. This solution was not only cost effective it was designed and installed on time and on budget. Thanks for being a vendor we can rely on.

 

Facility Manager

Magna Seating Detroit

 

 

We have been contracting The Safety Source to manage our MRO supplies with their state of the art vending software we have seen on average $6,000 per month savings! They also perform pallet racking repairs and installation and have always accommodated our busy production schedule and provided the best value.

 

Environmental Health & Safety Manager

Detroit Manufacturing Systems

 

 

Why Choose Us

Our team at Safety Source LLC are experts in designing and implementing pallet racking for various businesses, including retail, industrial, and warehousing.


During our design consultation, we make sure we understand your wants, needs, and desires entirely before designing a custom pallet racking solution that satisfies your business and makes the most efficient use of your current building layout.

 

Besides our fair quotes and quick turnaround, your project manager will stay in touch with you as much (or as little) as you desire. They’ll review the detailed CAD design plan, installation timeline, and detailed quotation. We want to ensure your stratification, and we believe the best way to do that is to stay in touch.

Companies We Work With

Buffalo Wild Wings
Magna
Fisher Dynamics
Diez Group
Neapco
Faurecia
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