Umlaufregallager

What is a carousel storage system?

A carousel storage system is a dynamic storage system in which shelving units – equipped with compartments, trays or bins – rotate motorically in a closed loop. Rather than employees walking through the warehouse, the required goods are brought fully automatically to a fixed retrieval point. This principle is known as goods-to-person and fundamentally distinguishes carousel storage systems from conventional flow or shelving racks.

There are two basic designs: horizontal carousel systems, in which shelf levels rotate along an elliptical path in the horizontal plane, and vertical carousel systems, in which trays or carrier systems are moved along a vertical circular path. The latter make more efficient use of building height and are frequently used where floor space is limited.

How does a carousel storage system work in practice?

The operation of a carousel storage system is closely coupled to a higher-level warehouse management system (WMS) or dedicated control software. As soon as a picking order is received, the software calculates the shortest path – i.e., the optimal direction of rotation – and moves the relevant storage location to the retrieval opening. The employee retrieves the goods, confirms the process at the terminal, and the system records the updated inventory.

Typical areas of application include:

• Spare parts and service warehouses with a high variety of SKUs
• Picking of small parts in e-commerce and retail
• Supply of components at assembly workstations
• Archiving of documents and physical data carriers

Access frequency in carousel storage systems is typically high. The automatic rotation eliminates searching and walking, which can significantly increase picking performance per employee. At the same time, ergonomics improve, as retrievals always take place at an ergonomically favorable working height.

What matters when making a selection?

When making an investment decision, several dimensions should be considered. First, the product structure: carousel storage systems are particularly suited to small to medium-sized items with high turnover frequency. Very heavy, bulky or temperature-sensitive goods require special solutions or other system types such as vertical lift modules or shuttle systems.

Second, WMS integration is critical: a carousel storage system only delivers its full benefit when it communicates bidirectionally with the leading warehouse management system. Interfaces, protocols and system response times are therefore core technical criteria.

Third, operations and maintenance should be calculated realistically: carousel storage systems are mechanically complex systems with moving parts that require regular maintenance intervals. The availability of spare parts, vendor support response times and the system's redundancy capability – for example in the event of a drive failure – significantly influence total cost of ownership. Fire protection requirements, particularly for enclosed housings, must be assessed separately depending on the goods stored and the building classification.

Finally, scalability must be considered: some systems can be extended retrospectively with additional carousel units, while others require complete redesign. This should be clarified during the tendering phase.