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Turnkey warehouse systems

Pallets into totes.
Totes into pallets.

Incoming pallets become tote stock and packed orders. Incoming totes can also be consolidated into outbound pallets. The goods, containers and two example tote transport carriers stay traceable through each handover.

Walk through the operation What we deliver
Connected transfersShared WCSMaintenance by design
Integration layoutTwo connected processes · double travel lanes · four lift units per storage system
Connected process map showing depalletising into totes, tote storage and packaging, plus tote-to-pallet consolidation and dispatch
Explore the routes and handovers in this integration example.
01 / The operation

Follow the goods through the handovers.

Choose pallet-to-package or tote-to-pallet. Watch the goods transfer, inspect the empty-container returns and compare the available equipment routes.

Engineering model render from Autodesk Fusion (concept, not a photograph)
Explore the operation

Pallet in → depalletise → totes → pack → packages out

Operating route
The connected operationConnected material flows · depalletising, tote fulfilment and palletisingpallet front-to-rear · P-L1-FORWARD, P-L2-FORWARD, P-L3-FORWARDpallet rear-to-front · P-L1-RETURN, P-L2-RETURN, P-L3-RETURNtote front-to-rear · T-L1-A-FORWARD, T-L2-A-FORWARD, T-L3-A-FORWARD, T-L4-A-FORWARD, T-L5-A-FORWARD, T-L6-A-FORWARDtote rear-to-front · T-L1-A-RETURN, T-L2-A-RETURN, T-L3-A-RETURN, T-L4-A-RETURN, T-L5-A-RETURN, T-L6-A-RETURNtote front-to-rear · T-L1-B-FORWARD, T-L2-B-FORWARD, T-L3-B-FORWARD, T-L4-B-FORWARD, T-L5-B-FORWARD, T-L6-B-FORWARDtote rear-to-front · T-L1-B-RETURN, T-L2-B-RETURN, T-L3-B-RETURN, T-L4-B-RETURN, T-L5-B-RETURN, T-L6-B-RETURNAA2BB2AA2BB2Pallet storageFour lifts · two one-way lanesTote storageTwo one-way lanes per bankPickingStock tote → order cartonPackingPallet dispatchPallet receivingTotes / cases inOrders outCase check & decantID / contour / massDepalletisingPalletisingOverhead view · arrows show one-way store lanes; stacked levels share a footprint.Transfer heightSelect a pallet or toteLoad streams & handoversPALLETStorage → dispatchTOTEStorage → pick → returnORDERPacking → dispatchPlanned storage pathUnavailable equipment
Pallet streamTote / order streamSelected routeUnavailable equipment
Input registered12
Still in process12
Dispatched0
Tracked item units12 · conserved

Goods remain on the inbound pallet until depalletising starts.

Connected goods. Separate containers.

The same goods move from the inbound pallet into totes, then into packed parcels.

Normal resources
Four tote lift units · paired one-way lanes
Selected resources
Four tote lift units · paired one-way lanes
Process output
Packed packages
Inspect engineering detail

Condition finding → planned routing

Review an illustrative condition finding before applying the selected process interruption.

Finding awaiting review.

Load records

WCS events

    Equipment and interface register
    Equipment IDInterfaceSupport height
    P-IN-APALLET RECEIVING A0.60 m
    P-CHECK-AP-CHECK-A · ID / contour / mass0.60 m
    P-DISPATCH-CHECK-AP-DISPATCH-A · wrap / ID0.60 m
    P-OUT-APALLET DISPATCH A0.60 m
    P-IN-BPALLET RECEIVING B0.60 m
    P-CHECK-BP-CHECK-B · ID / contour / mass0.60 m
    P-DISPATCH-CHECK-BP-DISPATCH-B · wrap / ID0.60 m
    P-OUT-BPALLET DISPATCH B0.60 m
    LIFT-P-A-GLIFT-P-A · ground port0.60 m
    LIFT-P-A2-GLIFT-P-A2 · ground port0.60 m
    LIFT-P-B-GLIFT-P-B · ground port0.60 m
    LIFT-P-B2-GLIFT-P-B2 · ground port0.60 m
    P-REJECT-APALLET EXCEPTION BAY A0.60 m
    P-REJECT-BPALLET EXCEPTION BAY B0.60 m
    LIFT-P-A-L1LIFT-P-A · level 12.40 m
    LIFT-P-A2-L1LIFT-P-A2 · level 12.40 m
    LIFT-P-B-L1LIFT-P-B · level 12.40 m
    LIFT-P-B2-L1LIFT-P-B2 · level 12.40 m
    P-L1-W-01P-L1-W-012.40 m
    P-L1-E-01P-L1-E-012.40 m
    P-L1-W-02P-L1-W-022.40 m
    P-L1-E-02P-L1-E-022.40 m
    P-L1-W-03P-L1-W-032.40 m
    P-L1-E-03P-L1-E-032.40 m
    P-L1-W-04P-L1-W-042.40 m
    P-L1-E-04P-L1-E-042.40 m
    P-L1-W-05P-L1-W-052.40 m
    P-L1-E-05P-L1-E-052.40 m
    P-L1-W-06P-L1-W-062.40 m
    P-L1-E-06P-L1-E-062.40 m
    P-L1-W-07P-L1-W-072.40 m
    P-L1-E-07P-L1-E-072.40 m
    P-L1-W-08P-L1-W-082.40 m
    P-L1-E-08P-L1-E-082.40 m
    LIFT-P-A-L2LIFT-P-A · level 24.80 m
    LIFT-P-A2-L2LIFT-P-A2 · level 24.80 m
    LIFT-P-B-L2LIFT-P-B · level 24.80 m
    LIFT-P-B2-L2LIFT-P-B2 · level 24.80 m
    P-L2-W-01P-L2-W-014.80 m
    P-L2-E-01P-L2-E-014.80 m
    P-L2-W-02P-L2-W-024.80 m
    P-L2-E-02P-L2-E-024.80 m
    P-L2-W-03P-L2-W-034.80 m
    P-L2-E-03P-L2-E-034.80 m
    P-L2-W-04P-L2-W-044.80 m
    P-L2-E-04P-L2-E-044.80 m
    P-L2-W-05P-L2-W-054.80 m
    P-L2-E-05P-L2-E-054.80 m
    P-L2-W-06P-L2-W-064.80 m
    P-L2-E-06P-L2-E-064.80 m
    P-L2-W-07P-L2-W-074.80 m
    P-L2-E-07P-L2-E-074.80 m
    P-L2-W-08P-L2-W-084.80 m
    P-L2-E-08P-L2-E-084.80 m
    LIFT-P-A-L3LIFT-P-A · level 37.20 m
    LIFT-P-A2-L3LIFT-P-A2 · level 37.20 m
    LIFT-P-B-L3LIFT-P-B · level 37.20 m
    LIFT-P-B2-L3LIFT-P-B2 · level 37.20 m
    P-L3-W-01P-L3-W-017.20 m
    P-L3-E-01P-L3-E-017.20 m
    P-L3-W-02P-L3-W-027.20 m
    P-L3-E-02P-L3-E-027.20 m
    P-L3-W-03P-L3-W-037.20 m
    P-L3-E-03P-L3-E-037.20 m
    P-L3-W-04P-L3-W-047.20 m
    P-L3-E-04P-L3-E-047.20 m
    P-L3-W-05P-L3-W-057.20 m
    P-L3-E-05P-L3-E-057.20 m
    P-L3-W-06P-L3-W-067.20 m
    P-L3-E-06P-L3-E-067.20 m
    P-L3-W-07P-L3-W-077.20 m
    P-L3-E-07P-L3-E-077.20 m
    P-L3-W-08P-L3-W-087.20 m
    P-L3-E-08P-L3-E-087.20 m
    C-IN-ACARTON RECEIVING A0.80 m
    C-CHECK-AC-CHECK-A0.80 m
    C-DECANT-AC-DECANT-A0.80 m
    T-DECANT-ADECANTED TOTE A0.80 m
    C-IN-BCARTON RECEIVING B0.80 m
    C-CHECK-BC-CHECK-B0.80 m
    C-DECANT-BC-DECANT-B0.80 m
    T-DECANT-BDECANTED TOTE B0.80 m
    C-REJECT-ACARTON EXCEPTION BAY A0.80 m
    C-REJECT-BCARTON EXCEPTION BAY B0.80 m
    LIFT-T-A-GLIFT-T-A · ground port0.80 m
    LIFT-T-A2-GLIFT-T-A2 · ground port0.80 m
    LIFT-T-B-GLIFT-T-B · ground port0.80 m
    LIFT-T-B2-GLIFT-T-B2 · ground port0.80 m
    LIFT-T-A-L1LIFT-T-A · level 11.45 m
    LIFT-T-A2-L1LIFT-T-A2 · level 11.45 m
    LIFT-T-B-L1LIFT-T-B · level 11.45 m
    LIFT-T-B2-L1LIFT-T-B2 · level 11.45 m
    T-L1-A-W-01T-L1-A-W-011.45 m
    T-L1-A-E-01T-L1-A-E-011.45 m
    T-L1-A-W-02T-L1-A-W-021.45 m
    T-L1-A-E-02T-L1-A-E-021.45 m
    T-L1-A-W-03T-L1-A-W-031.45 m
    T-L1-A-E-03T-L1-A-E-031.45 m
    T-L1-A-W-04T-L1-A-W-041.45 m
    T-L1-A-E-04T-L1-A-E-041.45 m
    T-L1-A-W-05T-L1-A-W-051.45 m
    T-L1-A-E-05T-L1-A-E-051.45 m
    T-L1-A-W-06T-L1-A-W-061.45 m
    T-L1-A-E-06T-L1-A-E-061.45 m
    T-L1-B-W-01T-L1-B-W-011.45 m
    T-L1-B-E-01T-L1-B-E-011.45 m
    T-L1-B-W-02T-L1-B-W-021.45 m
    T-L1-B-E-02T-L1-B-E-021.45 m
    T-L1-B-W-03T-L1-B-W-031.45 m
    T-L1-B-E-03T-L1-B-E-031.45 m
    T-L1-B-W-04T-L1-B-W-041.45 m
    T-L1-B-E-04T-L1-B-E-041.45 m
    T-L1-B-W-05T-L1-B-W-051.45 m
    T-L1-B-E-05T-L1-B-E-051.45 m
    T-L1-B-W-06T-L1-B-W-061.45 m
    T-L1-B-E-06T-L1-B-E-061.45 m
    LIFT-T-A-L2LIFT-T-A · level 22.10 m
    LIFT-T-A2-L2LIFT-T-A2 · level 22.10 m
    LIFT-T-B-L2LIFT-T-B · level 22.10 m
    LIFT-T-B2-L2LIFT-T-B2 · level 22.10 m
    T-L2-A-W-01T-L2-A-W-012.10 m
    T-L2-A-E-01T-L2-A-E-012.10 m
    T-L2-A-W-02T-L2-A-W-022.10 m
    T-L2-A-E-02T-L2-A-E-022.10 m
    T-L2-A-W-03T-L2-A-W-032.10 m
    T-L2-A-E-03T-L2-A-E-032.10 m
    T-L2-A-W-04T-L2-A-W-042.10 m
    T-L2-A-E-04T-L2-A-E-042.10 m
    T-L2-A-W-05T-L2-A-W-052.10 m
    T-L2-A-E-05T-L2-A-E-052.10 m
    T-L2-A-W-06T-L2-A-W-062.10 m
    T-L2-A-E-06T-L2-A-E-062.10 m
    T-L2-B-W-01T-L2-B-W-012.10 m
    T-L2-B-E-01T-L2-B-E-012.10 m
    T-L2-B-W-02T-L2-B-W-022.10 m
    T-L2-B-E-02T-L2-B-E-022.10 m
    T-L2-B-W-03T-L2-B-W-032.10 m
    T-L2-B-E-03T-L2-B-E-032.10 m
    T-L2-B-W-04T-L2-B-W-042.10 m
    T-L2-B-E-04T-L2-B-E-042.10 m
    T-L2-B-W-05T-L2-B-W-052.10 m
    T-L2-B-E-05T-L2-B-E-052.10 m
    T-L2-B-W-06T-L2-B-W-062.10 m
    T-L2-B-E-06T-L2-B-E-062.10 m
    LIFT-T-A-L3LIFT-T-A · level 32.75 m
    LIFT-T-A2-L3LIFT-T-A2 · level 32.75 m
    LIFT-T-B-L3LIFT-T-B · level 32.75 m
    LIFT-T-B2-L3LIFT-T-B2 · level 32.75 m
    T-L3-A-W-01T-L3-A-W-012.75 m
    T-L3-A-E-01T-L3-A-E-012.75 m
    T-L3-A-W-02T-L3-A-W-022.75 m
    T-L3-A-E-02T-L3-A-E-022.75 m
    T-L3-A-W-03T-L3-A-W-032.75 m
    T-L3-A-E-03T-L3-A-E-032.75 m
    T-L3-A-W-04T-L3-A-W-042.75 m
    T-L3-A-E-04T-L3-A-E-042.75 m
    T-L3-A-W-05T-L3-A-W-052.75 m
    T-L3-A-E-05T-L3-A-E-052.75 m
    T-L3-A-W-06T-L3-A-W-062.75 m
    T-L3-A-E-06T-L3-A-E-062.75 m
    T-L3-B-W-01T-L3-B-W-012.75 m
    T-L3-B-E-01T-L3-B-E-012.75 m
    T-L3-B-W-02T-L3-B-W-022.75 m
    T-L3-B-E-02T-L3-B-E-022.75 m
    T-L3-B-W-03T-L3-B-W-032.75 m
    T-L3-B-E-03T-L3-B-E-032.75 m
    T-L3-B-W-04T-L3-B-W-042.75 m
    T-L3-B-E-04T-L3-B-E-042.75 m
    T-L3-B-W-05T-L3-B-W-052.75 m
    T-L3-B-E-05T-L3-B-E-052.75 m
    T-L3-B-W-06T-L3-B-W-062.75 m
    T-L3-B-E-06T-L3-B-E-062.75 m
    LIFT-T-A-L4LIFT-T-A · level 43.40 m
    LIFT-T-A2-L4LIFT-T-A2 · level 43.40 m
    LIFT-T-B-L4LIFT-T-B · level 43.40 m
    LIFT-T-B2-L4LIFT-T-B2 · level 43.40 m
    T-L4-A-W-01T-L4-A-W-013.40 m
    T-L4-A-E-01T-L4-A-E-013.40 m
    T-L4-A-W-02T-L4-A-W-023.40 m
    T-L4-A-E-02T-L4-A-E-023.40 m
    T-L4-A-W-03T-L4-A-W-033.40 m
    T-L4-A-E-03T-L4-A-E-033.40 m
    T-L4-A-W-04T-L4-A-W-043.40 m
    T-L4-A-E-04T-L4-A-E-043.40 m
    T-L4-A-W-05T-L4-A-W-053.40 m
    T-L4-A-E-05T-L4-A-E-053.40 m
    T-L4-A-W-06T-L4-A-W-063.40 m
    T-L4-A-E-06T-L4-A-E-063.40 m
    T-L4-B-W-01T-L4-B-W-013.40 m
    T-L4-B-E-01T-L4-B-E-013.40 m
    T-L4-B-W-02T-L4-B-W-023.40 m
    T-L4-B-E-02T-L4-B-E-023.40 m
    T-L4-B-W-03T-L4-B-W-033.40 m
    T-L4-B-E-03T-L4-B-E-033.40 m
    T-L4-B-W-04T-L4-B-W-043.40 m
    T-L4-B-E-04T-L4-B-E-043.40 m
    T-L4-B-W-05T-L4-B-W-053.40 m
    T-L4-B-E-05T-L4-B-E-053.40 m
    T-L4-B-W-06T-L4-B-W-063.40 m
    T-L4-B-E-06T-L4-B-E-063.40 m
    LIFT-T-A-L5LIFT-T-A · level 54.05 m
    LIFT-T-A2-L5LIFT-T-A2 · level 54.05 m
    LIFT-T-B-L5LIFT-T-B · level 54.05 m
    LIFT-T-B2-L5LIFT-T-B2 · level 54.05 m
    T-L5-A-W-01T-L5-A-W-014.05 m
    T-L5-A-E-01T-L5-A-E-014.05 m
    T-L5-A-W-02T-L5-A-W-024.05 m
    T-L5-A-E-02T-L5-A-E-024.05 m
    T-L5-A-W-03T-L5-A-W-034.05 m
    T-L5-A-E-03T-L5-A-E-034.05 m
    T-L5-A-W-04T-L5-A-W-044.05 m
    T-L5-A-E-04T-L5-A-E-044.05 m
    T-L5-A-W-05T-L5-A-W-054.05 m
    T-L5-A-E-05T-L5-A-E-054.05 m
    T-L5-A-W-06T-L5-A-W-064.05 m
    T-L5-A-E-06T-L5-A-E-064.05 m
    T-L5-B-W-01T-L5-B-W-014.05 m
    T-L5-B-E-01T-L5-B-E-014.05 m
    T-L5-B-W-02T-L5-B-W-024.05 m
    T-L5-B-E-02T-L5-B-E-024.05 m
    T-L5-B-W-03T-L5-B-W-034.05 m
    T-L5-B-E-03T-L5-B-E-034.05 m
    T-L5-B-W-04T-L5-B-W-044.05 m
    T-L5-B-E-04T-L5-B-E-044.05 m
    T-L5-B-W-05T-L5-B-W-054.05 m
    T-L5-B-E-05T-L5-B-E-054.05 m
    T-L5-B-W-06T-L5-B-W-064.05 m
    T-L5-B-E-06T-L5-B-E-064.05 m
    LIFT-T-A-L6LIFT-T-A · level 64.70 m
    LIFT-T-A2-L6LIFT-T-A2 · level 64.70 m
    LIFT-T-B-L6LIFT-T-B · level 64.70 m
    LIFT-T-B2-L6LIFT-T-B2 · level 64.70 m
    T-L6-A-W-01T-L6-A-W-014.70 m
    T-L6-A-E-01T-L6-A-E-014.70 m
    T-L6-A-W-02T-L6-A-W-024.70 m
    T-L6-A-E-02T-L6-A-E-024.70 m
    T-L6-A-W-03T-L6-A-W-034.70 m
    T-L6-A-E-03T-L6-A-E-034.70 m
    T-L6-A-W-04T-L6-A-W-044.70 m
    T-L6-A-E-04T-L6-A-E-044.70 m
    T-L6-A-W-05T-L6-A-W-054.70 m
    T-L6-A-E-05T-L6-A-E-054.70 m
    T-L6-A-W-06T-L6-A-W-064.70 m
    T-L6-A-E-06T-L6-A-E-064.70 m
    T-L6-B-W-01T-L6-B-W-014.70 m
    T-L6-B-E-01T-L6-B-E-014.70 m
    T-L6-B-W-02T-L6-B-W-024.70 m
    T-L6-B-E-02T-L6-B-E-024.70 m
    T-L6-B-W-03T-L6-B-W-034.70 m
    T-L6-B-E-03T-L6-B-E-034.70 m
    T-L6-B-W-04T-L6-B-W-044.70 m
    T-L6-B-E-04T-L6-B-E-044.70 m
    T-L6-B-W-05T-L6-B-W-054.70 m
    T-L6-B-E-05T-L6-B-E-054.70 m
    T-L6-B-W-06T-L6-B-W-064.70 m
    T-L6-B-E-06T-L6-B-E-064.70 m
    PICK-APICK-A · stock tote0.80 m
    C-PICK-AORDER CARTON A0.80 m
    PACK-APACK / SCAN / SORT A0.80 m
    C-OUT-ACARTON DISPATCH A0.80 m
    PICK-BPICK-B · stock tote0.80 m
    C-PICK-BORDER CARTON B0.80 m
    PACK-BPACK / SCAN / SORT B0.80 m
    C-OUT-BCARTON DISPATCH B0.80 m
    P-DEPALL-INDepalletising pallet berth0.60 m
    P-PALLET-RETURNEmpty pallet return0.60 m
    T-DEPALL-1Depalletising tote berth 10.80 m
    T-DEPALL-2Depalletising tote berth 20.80 m
    P-PALLETISE-OUTPallet build and release berth0.60 m
    T-PALLETISE-1Palletising tote berth 10.80 m
    T-PALLETISE-2Palletising tote berth 20.80 m
    T-IN-1Tote receiving 10.80 m
    T-IN-2Tote receiving 20.80 m
    T-CHECK-1Tote identity check 10.80 m
    T-CHECK-2Tote identity check 20.80 m
    T-EMPTY-1Empty tote buffer 10.80 m
    T-EMPTY-2Empty tote buffer 20.80 m

    The demonstration tracks 12 illustrative item units. Container identities stay separate as the goods move between pallets, totes and parcels; this quantity is a demonstration batch, not an equipment rating. The pictured six-tier tote handling layout is a simplified integration example. Explore the magnetic-floor Tote ASRS product →

    02 / Equipment & interfaces

    Two processes. Connected equipment.

    Depalletising, tote transport, storage and packing form one process. Receiving totes and building outbound pallets forms the reverse process. The configuration follows the customer’s goods and application.

    Depalletising cell with a pallet intake, two tote fill interfaces and a separate empty-pallet return
    Pallet-to-tote handover. Engineering model render from Autodesk Fusion. Concept design, not a photograph.
    01 / Pallet → totes → packages

    Depalletise the load.
    Send the goods onward.

    The incoming pallet reaches the depalletising and decant cell. Its goods fill two identified totes. Two example tote carriers use the four available lift units for storage and retrieval; picking transfers the goods into parcels for packaging and dispatch.

    1. DepalletisePallet intake, counted goods transfer and empty-pallet return.
    2. Store & retrieveTwo example tote carriers, named tote locations and paired one-way travel lanes in each storage bank.
    3. Package & sendGoods enter parcel containers; empty totes return to reuse.

    The input pallet, each tote and each parcel have separate identities. Goods quantities reconcile across the handovers.

    Palletising cell with two tote intake berths, an outbound pallet build position and empty-tote returns
    Tote-to-pallet handover. Engineering model render from Autodesk Fusion. Concept design, not a photograph.
    02 / Totes → pallet

    Bring the totes together.
    Build the outbound pallet.

    Two incoming totes reach checked intake berths. Their goods are consolidated at the palletising cell. The completed outbound pallet follows the pallet dispatch route, while the empty totes return to their reuse interfaces.

    1. Receive totesTwo intake channels, identified loads and controlled release.
    2. PalletiseCounted goods transfer into one identified outbound pallet.
    3. Send & returnCompleted pallet to dispatch; empty totes to reuse.

    The pallet is released after both tote handovers complete. An unavailable cell holds its upstream loads.

    03 / Designed to be serviced

    Plan the interruption.
    Keep a route available.

    Maintenance belongs in the layout from the start: separated access, removable modules, identified connections and a physical alternative where the process allows it.

    Compare normal operation and lift maintenance
    01

    Exclude the unavailable lift

    WCS stops allocating the affected resource. The demonstrated load uses the other unit at the same end, or an available opposite-end route, to reach the same storage bay. Separate one-way lanes keep opposite travel directions apart; a blocked direction can still hold affected jobs.

    02

    Make the service job accessible

    Stairs, service decks, withdrawal space, handling aids and isolation are planned with the module. Access release follows the approved procedure.

    03

    Return with evidence

    Reconcile load positions, check equipment state and verify transfers before release. Sensor trends and AI findings help prepare the work.

    A surviving route has reduced resources. This example does not claim unchanged throughput or guaranteed availability.

    04 / Modular growth

    Start with one.
    Connect the next module.

    Add modules to see the storage, robots and handling paths increase. Then enter the equipment rates for the customer’s application and check which stage limits the flow.

    1 module

    Balance pallet receiving, tote storage, depalletising, palletising and dispatch around the customer’s order mix.

    Complete modules
    1
    Pallet places
    48
    Tote places
    144
    Tote robots
    2
    Tote in / out channels
    2 / 2
    Service stairs
    3
    Centreline layout span
    81 × 61 m
    Add capacity by repeating a complete module1 module · 48 pallet places · 144 tote placesModule M01Pallet baysTote handlingM01:STAIR-P · service landings 2.4 / 4.8 / 7.2 mM01:STAIR-P-OPPOSITE · service landings 2.4 / 4.8 / 7.2 mM01:STAIR-T · service landings 2.4 / 4.8 mAM01:ASRS-T-ABM01:ASRS-T-B48 pallet · 144 tote placesPallet backboneTote backboneSeparate service access
    Repeated integration-example 69 × 57 m integration modules; an 8 m gap reserves the connection and access arrangement.
    Robot and channel assignments
    ModuleRobotInbound channelOutbound channel
    M01M01:ASRS-T-AM01:T-FEED-AM01:PICK-A
    M01M01:ASRS-T-BM01:T-FEED-BM01:PICK-B

    The backbones connect actual ground interfaces. Each module retains its own storage, lifts, robots and service access. This is a modular assembly plan; the load walkthrough runs inside one module. Shared processing, packaging and dispatch must be sized for the combined demand. Adding storage does not establish a proportional throughput increase.

    1 module: 48 pallet places and 144 tote places.

    Fit the customer’s application

    Size the flow, stage by stage.

    Enter the equipment rates for your project. Every stage is compared in goods items per hour, with the required container moves included.

    The pictured batch uses 12 illustrative item units. Replace these goods quantities and enter agreed equipment rates. Example duty: putaway, retrieval and empty return use three robot moves; storage uses two loaded lift moves. Change the duty factors to match the application.

    Enter the stage rates to see the limiting equipment.

    This is a steady-flow sizing estimate. Shared receiving, packaging and dispatch remain shared as modules are added. Availability, mixed order profiles, buffers and queueing need a workload test; these entries are not measured machine ratings.

    05 / The delivery scope

    Configure the application.
    Then define the delivery.

    Equipment, controls, building interfaces and service requirements are agreed together. Acceptance is based on the real loads and operating cases.

    1. 01

      Understand the operation

      Load matrix, peak demand, inventory, building survey, docks and maintenance constraints.

    2. 02

      Engineer the interfaces

      Storage selection, transfer heights, buffers, guards, access and recovery routes.

    3. 03

      Connect equipment & control

      Machine handshakes, WCS tracking and reservations, sensors and customer-system interfaces.

    4. 04

      Install, test & hand over

      Load and fault tests, agreed performance acceptance, training, spares and service documentation.

    Configuration and engineering notes

    The module shows depalletising/decant, two example tote transport carriers, storage and retrieval, parcel packaging, reverse palletising, empty-container returns and separate service access. Pallet service stairs stand on opposite sides, with connected decks and bridges at every human service floor. Stair flights alternate sides by service floor, with a connected landing on each walkable level. Tote shelf tiers are not human walkways. Geometry and software checks are separate from payload, structure, guarding, fire protection and physical acceptance.

    Open the detailed geometry views →
    Start with your operation

    What needs to move?

    Share the goods, demand, building and service needs. We will use them to define the equipment and interfaces for your project.

    Contact us
    +44 20 8057 6227info@sapientech.co.uk