We’re here to answer your frequently asked questions about vertical carousels. These automated material handling systems are designed to increase efficiency, maximize space, and streamline operations for a variety of industries. Within these FAQs about warehouse carousels, we’ll break down their key benefits, how they operate, and more. Whether you’ve only just heard about carousels or you’re already evaluating implementing one in your facility, we hope these FAQs provide awareness and insight about these incredibly effective automation storage solutions.
General Questions
What is a storage carousel and how does it work?
A storage carousel is an automated storage and retrieval system that uses a motor and an enclosed track to rotate trays or carriers internally, delivering and presenting items to a pick window. These vertical carousels are high-density storage solutions that speed up the picking process and make operations more efficient.
What types of warehouse carousels are available?
There are vertical carousels and horizontal carousels. Like their name states, vertical carousels rotate vertically, or up-and-down, while horizontal carousels rotate horizontally, moving storage carriers side-to-side.
What industries commonly use warehouse carousels?
All types of industries can benefit from storage carousels as these systems are capable of storing a wide variety of small to medium sized items. Common industries we see using these automation solutions for inventory management, spare parts, and order fulfilment include e-commerce, manufacturing, especially aerospace, automotive, and many others.
How do warehouse carousels improve storage efficiency?
Carousels, specifically the Hanel Rotomat, provide over 60% floor space savings, in some cases up to 85%, by making the most of your clear height. These automation solutions utilize customizable multifunction carriers to create an ultra-high-density storage solution whose pick window reduces walking time, enabling the retrieval process to be faster and safer for workers.
What is the difference between horizontal and vertical carousels?
Vertical carousels are ideal for facilities wanting to take advantage of their ceiling height, using all vertical space available. Horizontal carousels typically have a higher weight limit but occupy a good amount of floor space, making them ideal for space constrained facilities with minimal clear height.
Benefits of Warehouse Carousels
What are the main benefits of using a warehouse carousel system?
The main benefits of a warehouse carousel system include space savings, inventory accuracy and awareness, faster picking times and general productivity increase, improved ergonomics, and inventory security.
How much space can a warehouse carousel save compared to traditional shelving?
Depending on the type of carousel you choose, these automation solutions can save up to 85% floor space. The footprint of a carousel is typically between 32-65 sq ft.
Can warehouse carousels reduce labor costs and picking time?
Yes, vertical carousels can reduce labor costs as strenuous activity is not required to retrieve an item, including no-more bending and retrieving items from low levels or using a ladder to retrieve items from a high shelf. Additionally, walking time is drastically reduced.
What is the typical ROI for installing a warehouse carousel?
Depending on the application, most businesses can expect a ROI within 12-18 months, sometimes even less than 12 months. ISS Material Handling’s experienced sales representatives can evaluate your inventory metrics and provide an accurate ROI in order to help understand the financial benefits of this sort of investment.
Technical and Operation
How much weight can a warehouse carousel hold?
A carousel’s weight capacity varies by model but the Hanel Rotomat offers payloads of up to 1,653 lbs and total payloads of up to 30,865 lbs.
What is the height of a carousel?
Carousels will vary in height, but will fit into buildings with clear heights less than 26 feet high. This height ensures that the carousel remains balanced.
What are the power and maintenance requirements for warehouse carousels?
Vertical carousels require standard electrical power and routine maintenance to keep it up and running long term. The Hanel Rotomat also takes advantage of proprietary EcoLoad technology to utilize a well-balanced machine, resulting in very little energy needed to move the system.
Can carousels integrate with warehouse management systems (WMS)?
Warehouse carousels such as the Hanel Rotomat will integrate with warehouse management systems and ERP systems. Additionally, this system can create exclusive access for specific personnel to specific areas of the machine either by keycard or keycode, keeping high-value inventory secure.
How fast do warehouse carousels operate compared to manual picking?
Carousels have picking speeds of 100-400 items per hour. This is more efficient than manual picking, which often requires time spent walking and searching for an item. Hanel Rotomats used in high-speed picking scenarios can be equipped with a high-speed picking package resulting in 70% improved rotation speeds.
Cost and Installation
What is the average cost of a warehouse carousel system?
Costs of vertical carousels varies by size, however is not typically that different than a Vertical Lift Module, which for a similar price can potentially store more material at greater heights at the expense of a much larger footprint and slightly longer retrieval times. Chat with your St. Louis automotive expert at ISS Material Handling to find out more about investment.
How long does it take to install a warehouse carousel?
Installation of a vertical carousel typically takes 2-6 weeks depending on customization needed, including ERP integration and personnel training.
Learn More About Carousels
Have more questions or want to learn about what a carousel would look like in your facility? Talk to your St. Louis automotive expert at 833-754-2164 or fill out a form here, and someone will get back to you.
About the Author
John Fontaine
Automation Sales Lead
After a 9 year career as an officer in the US Navy Submarine Force, John developed vital experience in the advanced manufacturing and unmanned systems with business development roles at two major defense contractors. In directing the growth of ISS Material Shelving, a division of Industrial Shelving Systems, John’s mission is clear: to remain thoroughly customer-focused, ensuring that businesses who partner with ISS Material Handling seize the right opportunities for automation adoption, fueling responsible growth amidst challenging economic circumstances. When not in the office, John enjoys all things music, cooking, and fitness.