Automated Storage and Retrieval Systems (ASRS)

What Are Automated Storage and Retrieval Systems?

Automated storage and retrieval systems (AS/RS) are computer-controlled machines that automatically place items into storage and retrieve them when needed. Instead of storing items on conventional shelving or pallet racks where workers must walk, search, and pick manually, ASRS systems use vertical space and automated delivery to bring items directly to the operator at an ergonomic access point.

The core concept behind ASRS is product-to-person (also called goods-to-person) storage: the machine moves items to the worker rather than the worker moving to the items. This approach can reduce the floor space required for storage, speed up order picking and retrieval, improve inventory accuracy, reduce labor costs, and keep valuable or sensitive items more secure.

ASRS systems are used across many industries including automotive, manufacturing, warehousing, healthcare, retail, aerospace, government, and any environment where efficient storage and fast retrieval of parts, products, or materials is important.

How ASRS Works: Goods-to-Person Storage

In a goods-to-person ASRS system, items are stored inside an enclosed machine on trays, shelves, or carriers. When an operator needs an item, they enter a request at the control panel or through software. The machine locates the tray or carrier containing that item and delivers it to the access window at the operator’s workstation. The operator picks the item, and the tray returns to storage.

This eliminates walking time, searching time, and the errors that come with manual picking from conventional shelving. It also means that inventory is stored in a closed, controlled environment rather than on open shelves where items can be misplaced, damaged, or taken without authorization.

Different types of ASRS systems handle different item types, sizes, weights, and volumes. The right system depends on what you are storing, how often you need to retrieve it, how much floor space is available, and the throughput requirements of your operation.

Vertical Lift Modules (VLM)

A vertical lift module (VLM) is an enclosed ASRS unit with two columns of trays and an automated inserter/extractor in the center. Items are stored on trays that the machine lifts and delivers to the access window when requested. VLMs use the full height of the building, storing items from floor to ceiling in a compact footprint.

Vidir VLM systems can recover up to 85% of the floor space compared to conventional shelving or racking for the same amount of inventory. The machine measures each tray’s contents and optimizes vertical spacing automatically, so no space is wasted above items that do not fill the full tray height.

VLMs are widely used in auto parts rooms, manufacturing tool cribs, maintenance supply rooms, aerospace component storage, and any application where many small to medium-sized items need to be stored and retrieved efficiently.

See our auto parts room VLM solutions for a detailed look at VLM applications in automotive environments.

Vertical Carousels

Vertical carousels, also called pan carousels, use a series of carriers (pans) attached to a rotating chain inside an enclosed cabinet. When an item is requested, the chain rotates to bring the correct carrier to the access window. Vertical carousels are a simpler and often more cost-effective automated storage option compared to VLMs.

Vidir vertical carousels can recover up to 75% of the floor space used by conventional shelving. They are a good fit for operations that need automated storage but have a more moderate throughput requirement or a lower ceiling height than a VLM installation would need.

Common applications include parts storage, document and file storage, tool management, retail backstock, and small parts distribution.

Tire Carousels

Tire carousels are a specialized ASRS product designed specifically for tire storage and retrieval. Auto dealerships, tire shops, fleet maintenance facilities, and warehouses that store seasonal or customer tires face a common problem: tires take up enormous floor space when stored on conventional racks or in ground-level stacks.

The Vidir tire carousel stores tires vertically on rotating carriers inside an enclosed structure. The system can recover up to 70% of the floor space compared to ground-level tire storage. When a tire set is needed, the carousel rotates to deliver the correct carrier to the access point, eliminating manual searching and heavy lifting.

Tire carousels also improve tire condition by storing them in an organized, upright position rather than stacked or leaned against walls where damage can occur.

Interested in Automated Storage for Your Facility?

Material Handling USA supplies the full range of Vidir ASRS products. Tell us what you need to store, and we will help you find the right automated solution.

Automated Locker Systems

Automated locker systems combine secure storage with automated access control. Items are stored in individually locked compartments that open only when the authorized user requests access. Automated lockers are used for tool checkout, IT equipment management, PPE distribution, parts kitting, and retail order pickup.

Unlike open shelving or manual tool cribs, automated lockers track who accessed what and when, creating accountability and reducing shrinkage. They can be integrated with employee badges, PIN codes, or barcode scanning for access control.

See our smart locker solutions for more automated locker options.

Bar Stock Vertical Lift Storage

Bar stock, pipe, tubing, and other long materials are difficult to store efficiently on conventional racks. They take up long runs of floor space, create tripping hazards, and are awkward to handle manually. Bar stock vertical lift storage systems store long materials vertically in an enclosed unit and deliver them to the operator at an ergonomic access height.

This approach dramatically reduces the floor space needed for long material storage and eliminates the safety risks associated with manual handling of long, heavy bars and tubes.

Sheet Metal Vertical Lift Storage

Sheet metal, plate stock, and flat panel materials present similar storage challenges as bar stock: they require large floor areas, are heavy and awkward to handle, and can be easily damaged when stacked or leaned. Sheet metal vertical lift storage systems store flat materials in carriers that are lifted and delivered to the operator automatically.

This keeps sheet material organized, protected from damage, and accessible without forklifts or overhead cranes for routine retrieval.

Wire, Shelving, Garment, and Carpet Carousels

Vidir manufactures specialized carousel systems for specific product types that do not fit standard VLM or carousel configurations:

• Wire and cable carousels: Store reels of wire and cable vertically and dispense material by the foot or spool without manual handling of heavy reels.
• Garment carousels: Store hanging garments (uniforms, costumes, retail inventory) in vertical rotating systems that bring the correct garment to the access point on demand.
• Carpet and roll goods carousels: Store rolls of carpet, fabric, vinyl, or other roll goods vertically and deliver selected rolls to the operator without forklifts or overhead handling.
• Shelving carousels: General-purpose rotating shelving systems for retail backstock, library materials, files, or mixed small parts.

Healthcare and Pharmacy Storage

Hospitals, pharmacies, clinics, and healthcare supply chains use ASRS systems to store medications, medical supplies, surgical instruments, and other items that require secure, organized, and trackable storage. VLMs and vertical carousels in healthcare settings reduce the time nurses and pharmacists spend searching for supplies, improve inventory accuracy, and support controlled substance tracking.

Automated storage in healthcare environments can also help reduce expired product waste by enabling first-in-first-out (FIFO) inventory rotation and making it easier to audit stock levels.

Retail Pickup and E-Commerce Fulfillment

ASRS systems are increasingly used in retail and e-commerce environments for order fulfillment and customer pickup. VLMs and automated lockers can store products in compact footprints behind the counter or in backroom areas, delivering items to staff for packing or directly to customers at pickup kiosks. This is particularly useful for buy-online-pickup-in-store (BOPIS) operations and high-value retail items that need secure storage.

ASRS System Comparison

Space recovery percentages are based on Vidir Solutions product information and represent maximum potential recovery compared to conventional storage methods. Actual results vary by application, configuration, and existing storage layout.

Not Sure Which ASRS System Is Right for You?

Tell us what you store, how often you pick, and how much floor space you have. Material Handling USA will recommend the right Vidir ASRS system for your operation and provide a quote.

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How to Choose an ASRS System

Selecting the right automated storage and retrieval system depends on several factors specific to your operation:

• What are you storing? Small parts, tools, tires, bar stock, sheet metal, garments, and other items each have specialized ASRS solutions.
• How many picks per hour? High-throughput operations may benefit from VLMs or dual-access configurations, while lower-volume operations may be well served by vertical carousels.
• How much floor space is available? ASRS systems use vertical space instead of floor space. Ceiling height is a key factor in determining how much storage capacity you can achieve.
• What is the weight per item? VLMs and carousels have tray and carrier weight capacities that need to match the items being stored.
• Do you need access tracking? Automated lockers and VLMs with user authentication provide full access logs for accountability and inventory control.
• Multiple access points? Some VLMs support dual-access configurations where items can be loaded from one side and picked from another for workflow separation.
• Budget and timeline: Different ASRS types have different cost ranges and lead times. Discuss your budget early so we can recommend the best-value solution for your needs.

Why Choose Material Handling USA for ASRS?

Related Products

• Vertical and Modular Storage for Auto Parts Rooms for VLM and carousel applications in automotive environments.
• Vidir Vertical Storage Solutions for the full Vidir product line overview.
• Mobile Shelving for high-density storage using compact mobile aisle systems.
• Shelving Solutions for conventional and industrial shelving options.
• Smart Lockers for automated locker and asset management solutions.

Frequently Asked Questions

Ready to Automate Your Storage?

Material Handling USA supplies the full Vidir ASRS product line. Whether you need a single VLM for a parts room or a multi-unit automated storage system for a warehouse, we can help you plan, configure, and implement the right solution.