Karusselllager

What is a carousel storage system?

A carousel storage system is a motor-driven storage system in which bins, trays, or compartments revolve on a closed carrier and are transported to the retrieval opening on demand. The principle follows the goods-to-person approach: the operator remains at a fixed workstation while the system automatically moves to the required storage position. This significantly reduces travel times and physical strain compared to conventional shelving systems.

Two basic designs are distinguished: In a horizontal carousel, the storage carriers rotate on an oval track in the horizontal plane — similar to a racetrack. This design is relatively cost-effective but requires a large floor area. The vertical carousel, also known as a paternoster, moves the compartments in a vertical loop, making use of the available ceiling height while requiring less floor space. Both variants are particularly suited to small parts, spare parts, documents, and items with manageable dimensions and moderate weight.

How does a carousel storage system work in practice?

The picking process begins with an order in the warehouse management system or material flow controller. The system calculates the shortest path to the required position and rotates the carousel accordingly. At the retrieval opening, a light display (pick-to-light) or screen indicates the exact quantity to be picked and the relevant compartment. This allows error rates to be significantly reduced without necessarily requiring complex scanning technology — although barcode or RFID confirmation is common in many installations.

Multiple carousels are often combined (batch operation), allowing a single operator to pick alternately from different units while the other system is already moving to the next position. This so-called interleaving noticeably increases the effective picks per hour. Integration with a warehouse management system is standard; however, the depth of WMS integration and available interfaces vary depending on the vendor.

What should you consider when making a selection?

When deciding on a carousel storage system, several factors should be carefully weighed:

• Item range: The size, weight, and sensitivity of items determine whether a horizontal or vertical carousel is appropriate and what tray or bin configuration is required.
• Throughput and access frequency: Carousels are designed for medium to high access frequencies; for very infrequent access, the automation investment may not be economically justified.
• Space situation: Horizontal systems require floor space, while vertical systems need sufficient clear ceiling height — both aspects must be considered in building planning.
• Scalability: Check whether additional carousel units can be added later and how the system responds to a growing product range or increasing volume.
• Maintenance and spare parts supply: Carousel systems are mechanically complex; maintenance contracts, spare parts availability, and the manufacturer's response times are relevant selection criteria.

Compared to a vertical lift module or an automated small-parts warehouse (AS/RS), the carousel storage system is typically positioned in the mid-range investment bracket. Which solution is more cost-effective depends heavily on the specific item mix, inventory depth, and floor space costs — blanket recommendations are not appropriate here.