What is a pick module and when should I add one?
Quick Answer
A pick module is a warehouse optimization solution; a multi-level rack and conveyor zone that feeds high-volume SKUs to pickers while bulk pallets sit above or behind. Add one when rising order lines, costly travel time, or limited floor space demand faster, denser order fulfillment without relocating or fully automating the entire warehouse.
Detailed Answer
A pick module is essentially a rack-supported mezzanine that funnels product from bulk storage to fast-moving pick faces. During layout design and distribution center optimization projects, we often deploy these modules to shorten picker travel and concentrate SKUs by velocity. Multiple levels of selective or pallet flow rack feed gravity lanes or conveyors so pickers can grab cartons quickly while replenishment happens behind the scenes. By stacking pick positions vertically, you multiply SKU capacity without expanding the building footprint.
You should consider adding one when e-commerce order lines are climbing, travel time dominates labor costs, or seasonal peaks strain floor-level shelving. A pick module is also ideal when you plan to introduce conveyor sortation or automated storage and retrieval systems (AS/RS) but need a phased approach. Warehouse Cubed’s warehouse optimization team can model throughput, design the racking, and integrate carton flow, conveyor systems, lighting, and safety guarding in a turnkey package. Because we handle material handling systems integration, permitting, and installation nationwide, you get one accountable partner and faster payback. Most clients recover the investment in 12–24 months through reduced labor, higher pick accuracy, and deferred building expansion.