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What is a tray storage system?

A tray storage system is a storage system that uses flat, standardized load carriers – known as trays – as the central storage unit. These trays accommodate small parts, spare parts, or items with irregular shapes, enabling organized, space-efficient storage. Unlike bin storage systems, which are based on boxes or plastic containers, trays offer an open, flat surface suited to items that do not fit well into closed containers or that require particularly fast access.

How does a tray storage system work in practice?

Tray storage systems are available in both manual and automated variants. Automated systems frequently operate as goods-to-person solutions: a storage and retrieval machine or comparable conveyor system transports the requested tray from the rack directly to the picking workstation. There, the operator picks the required quantity before the tray is automatically returned to storage. This process significantly reduces travel times and increases picking accuracy, since only one tray is present at the workstation at any given time.

Manual tray storage systems are simpler in design: trays sit in racks, and staff retrieve the required units themselves. Such systems are more flexible in terms of layout, but less capable at high throughput.

• Typical application areas include spare parts logistics, e-commerce order picking, and assembly and kitting supply.
• Trays are produced in common standard dimensions, meaning that system components from different manufacturers may be combinable – however, actual compatibility depends on the vendor and should be verified during the selection process.
• Storage control is handled by a warehouse management system that manages tray positions, item assignments, and picking orders.

What matters when making a selection?

Several factors are critical when planning a tray storage system. First, the tray format determines which items can be stored effectively; the size, load capacity, and material of the trays should match the product range. Second, the degree of automation significantly influences the investment required – fully automated systems are more capital-intensive, but pay off more quickly at high throughput and multi-shift operations. Third, the scalability of the system should be considered: if the assortment grows, the storage system must be expandable without interrupting ongoing operations. Finally, maintenance requirements, spare parts availability, and manufacturer support play an important role in the total cost of ownership – aspects that can vary considerably depending on the vendor.