Can an AS/RS work with mixed pallet sizes and weights?
Quick Answer
Yes. Modern automated storage and retrieval systems can be engineered to handle mixed pallet sizes and weight ranges. Warehouse Cubed designs AS/RS solutions with adjustable load-handling devices, dynamic weight sensing, and smart software rules so each pallet—light or heavy, short or tall—moves safely and efficiently through the same automated aisle.
Detailed Answer
Automated storage and retrieval systems (AS/RS) are engineered to accommodate a broad range of pallet footprints and load capacities.
Telescopic forks, variable-width shuttles, and crane grippers fitted with load cells automatically measure each inbound pallet, confirm that weight is within limits, and adjust their stroke so mixed sizes ride smoothly. The supervisory software then assigns a location based on real-time space, ensuring light pallets aren’t buried under heavier ones and oversized pallets are steered to deeper bays or wider channels.
Through Warehouse Cubed’s warehouse consulting services, our team evaluates your SKU mix, current racking, and future growth targets to specify the right configuration. We refine rail spacing, clearances, and cycle speeds during warehouse layout design, then tie the new equipment into your existing WMS or ERP as part of our material handling systems integration program. Optional checks—such as vision scanners that flag damaged pallets, dimensioning tunnels, and dynamic weight tracking—extend equipment life and keep OSHA limits in check.
The result is a flexible, high-density automation platform that combines multiple pallet standards in one footprint instead of separate rack zones. You gain faster put-away and retrieval, tighter inventory control, and a safer work environment while reducing labor and travel time. When peak season or a new product line arrives, the same AS/RS simply updates slotting rules—no costly re-racking required.