Maximizing Efficiency with Carousel Warehouse Systems

To properly manage a warehouse, you must focus on efficiency. Maintaining high efficiency and productivity rates allows you to increase your company’s revenues and profits. There are many types of technologies that can make a warehouse or distribution center more efficient. One piece of technology that might interest you is a carousel warehouse system.

Warehouse carousel systems are goods-to-person devices that you can use to effectively move inventory throughout your facility. Along the way, the items can be picked, packaged, and shipped to your customers. Once you install a carousel system in your warehouse, you’ll benefit from higher throughput, better efficiency, and more storage density.

Carousels consist of rotating shelves that can move horizontally or vertically. Modern systems can be integrated directly into warehouse management software, which allows for more effective control of inventory levels. A carousel can accommodate a picking rate of as many as 400 lines every hour, which can be helpful for companies that need to store and process items quickly.

When comparing carousel systems to traditional storage methods, static solutions are inefficient. They take up more space than carousel systems and waste too much time during the picking and packing processes.

There’s also a higher risk of safety hazards when using traditional storage methods. Whether items fall from shelves or employees become injured by lifting heavy loads, numerous issues can be mitigated by switching to a carousel system. In this guide, you’ll learn about how to optimize your storage and boost efficiency with carousel warehouse systems.

Types of Carousel Warehouse Systems

There are two types of warehouse carousel systems that you can install in your facility, which include a vertical system and a horizontal one. The type you choose depends on your layout as well as the applications the system is being used for.

Horizontal Carousel Systems

A horizontal carousel system is comprised of an oval track as well as numerous bins where items can be placed. The bins are adjustable to ensure products of different sizes can fit without issue. It’s also possible to remove the bins and replace them with drums, hanging garments, totes, or boxes depending on the application.

If you decide to buy a horizontal carousel for your facility, you have a few options to choose from, which include a standard system and a robotic carousel. A standard carousel allows items to be placed and picked manually for a more efficient process. The number of carousels you obtain depends on the throughput you require.

You can also install a robotic horizontal carousel in your warehouse. This is a type of automated carousel that uses a robotic picking arm to improve efficiency.

Horizontal carousels can be used for a wide range of applications, the most common of which include consolidation, fulfillment, and buffering. Order consolidation takes up a lot of floor space, which can be avoided with horizontal carousels. Workers can pick items and place them on the carousel to assist with consolidation.

The automation software in your warehouse will sort product bins to minimize mistakes. Workers can batch products without being tasked with walking and searching for different items. Once you install a horizontal carousel, measure the amount of time the picking and packing processes take to determine how much this system improves productivity.

Vertical Carousel Systems

You can maximize the space in your facility by installing vertical carousel systems, which are automated to provide personnel with a quick way to reach different products. These systems are made with enclosed automated shelving that rotates based on preprogrammed instructions from the operator. They reduce the amount of time your employees take when consolidating products and fulfilling orders.

Once you install this system, you’ll be able to move products to your workers without ladders or forklifts. When you have static shelving systems in your warehouse, you’ll need to use more space for aisles. Vertical carousels are designed to minimize your operational footprint and help you store products that come in various shapes and sizes.

This type of carousel is effective when paired with a wide range of applications. You can effortlessly integrate the carousel into your warehouse management software to ensure you can pick and track items without issue. When an employee requests a specific item, the vertical shelving will move into the proper position for simple picking. Consider using vertical carousels for applications like:

• Batch picking
• Work in progress
• Order fulfillment
• Order consolidation

The shelves in vertical carousels can be customized to suit your specific needs. For example, you can use different types of storage on each level.

Benefits of Implementing Warehouse Carousel Systems

This type of setup offers ample benefits for your storage needs, which include everything from space optimization to improved worker safety. As mentioned previously, there are usually many more safety hazards with a traditional storage system. Your employees will no longer need to worry about lifting items at odd angles or products falling off shelves. Warehouse carousel systems allow for a much more efficient and streamlined picking process that promotes worker safety.

Carousel warehouse systems can also increase productivity by automating a large portion of the picking and consolidating processes. You can save up to 70% of required labor hours once you install a carousel system in your warehouse. Keep in mind that these systems typically provide a high ROI. While the upfront costs might be more than expected, you’ll save money every day by making your operations more efficient.

Horizontal carousel systems allow workers to load items with ease, which substantially limits the amount of time that’s wasted walking around and picking products from different shelves around your warehouse. When you use a vertical carousel, your personnel can input a specific item number into the system’s control panel to obtain the product in seconds. You should save thousands of dollars every year.

These systems can also help you reduce the amount of space that’s used for inventory in your facility. Carousels are designed to assist with space optimization. They are highly efficient and are capable of managing numerous products and SKUs. These systems build upward, which means that warehouses with higher ceilings benefit the most from this type of carousel. You can store thousands of unique items with vertical carousels.

Considerations for Choosing a Carousel System

Before you buy a carousel system for your warehouse, there are numerous factors you must consider. Identify your business needs and space constraints to find the system that’s right for you. When assessing the space in your facility, measure the total floor area, which includes the height of your ceiling. If you have a low ceiling, it might be a good idea to use a horizontal carousel. Vertical carousels are suitable for more confined spaces that don’t have a lot of square footage to work with.

It’s also important that you evaluate the layout of your facility to find an area that makes the most sense for the installation of a carousel warehouse system. Make sure it’s installed in an area where pickers have easy access to your products. Consider picking speed as well. The distribution industry requires fast pick speeds, which means that you need a system that can help you reach a higher pace without encountering delays or setbacks.

Load capacity is another important factor. Each carousel has a different maximum capacity. Estimate the average size and weight of the products you intend to store on the carousel. If you store oddly shaped products like tires, you may need to customize the carousel to accommodate the unique design.

When calculating the load capacity that’s needed in your facility, think about how full the horizontal or vertical carousel will get at the busiest time of the day. By better understanding the inventory types and volumes that you’ll be working with, you can obtain a carousel warehouse system that meets your operational needs.

If you have an existing warehouse management system (WMS) in your facility, make sure you can seamlessly integrate it with your carousel of choice. Vertical carousels are typically designed with WMS integration in mind.

It’s also highly recommended that you consider your budget when searching for the ideal carousel system. As touched upon previously, the efficiency gains you’ll benefit from after installing this system should help you save a lot of money in the long run. However, the initial costs can be high. The amount of money you spend depends on the type of system you buy. These machines usually start at around $50,000 but can cost more than $150,000.

Installation and Maintenance of Carousel Warehouse Systems

The installation process for a carousel system depends on the specific type that you buy for your warehouse. If you select a vertical carousel, the company that ships it to you may also provide installation. These systems are assembled on-site. You can expect the installation process to take an entire day. Debug the carousel after installation to make sure it runs properly.

Because carousel systems combine mechanical, electrical, and control components, installation and major maintenance should be performed by qualified technicians. Facilities should also follow OSHA’s machine guarding requirements to ensure moving carousel components are properly guarded to protect operators during normal use.

If you ever have a problem with your carousel system, it may be related to a bug in your warehouse management software. There’s also a chance that your personnel are incorrectly loading items. Vertical carousels often encounter balancing issues, which can result from different product weights and sizes being stored improperly.

You can reach optimal performance by maintaining the system regularly. Inspect the wheels, tracks, wiring, and other components to make sure everything’s working properly. The chains and tracks should also be lubricated whenever you inspect the system. Most carousel systems come with manufacturer instructions about how to implement ongoing maintenance.

Frequently Asked Questions

What is the difference between horizontal and vertical carousel systems?

Horizontal carousels rotate bins along a horizontal track at roughly waist height, while vertical carousels rotate trays vertically within an enclosed column, making better use of ceiling height in facilities with limited floor space.

How much floor space can a carousel system save?

Carousel systems can reduce the floor space needed for storage significantly compared to traditional shelving, since they use vertical space and bring inventory to the operator instead of requiring aisles for picker access.

Are carousel systems compatible with warehouse management software?

Yes. Most modern carousel systems can integrate with warehouse management or inventory control software, and many can be paired with pick-to-light systems to further improve picking speed and accuracy.

How often does a carousel system need maintenance?

Routine maintenance, such as checking drive belts, chains, and bearings, is typically recommended on a quarterly or semi-annual basis, though usage intensity and manufacturer recommendations should guide the exact schedule.

What types of products are best suited for carousel storage?

Carousel systems work well for small to medium-sized parts, components, and SKUs with moderate to high pick frequency, such as electronics, spare parts, and retail or e-commerce fulfillment items.

Conclusion

Warehouse carousel systems deliver increased productivity, improved worker safety, better inventory management, and effective space optimization. By pairing a carousel system with your facility’s WMS, you can automate a sizable portion of your picking, consolidating, and fulfillment processes. If you decide to utilize carousel systems in your facility, they must be installed correctly to avoid downtime and other efficiency problems. Explore carousel solutions today to find a system that meets your company’s needs.