vertical carousel storage system

Vertical and Horizontal Carousel Storage Systems

The implementation of Vertical and Horizontal Carousel Storage Systems has increased significantly over the past few years, as warehouses that require solutions for parts delivery, high speed automated picking or sortation applications search for long-term answers. What these systems have enabled companies to do is improve speed of storage and retrieval of goods in a way that is both cost-effective and reliable without having to compromise.

How It Works

A Horizontal Carousel system is, in simple terms, a succession of wire bins and shelves attached to an oval track which rotates to deliver the requested inventory to each individual operator. To ensure complete operational efficiency, they are typically used in pods. A pod consists of at least two horizontal carousels used in a workstation that utilises software and pick-to-light technology. This means when the operator is picking from one carousel, the other is positioning itself ahead of the next pick, shortening operational downtime.


The reason horizontal carousels are used in conjunction with pick-to-light technology is that it allows the operator to be guided towards the exact location of the next pick. The light tree highlights where to pick from next and the exact quantity required.

This is particularly helpful when it comes to batch picking, which used in conjunction with inventory management software, enabling the operator to pick multiple orders simultaneously. For example, when the horizontal carousel displays a stockkeeping unit, the operator can select how many is needed for each order before distributing.

The reduction in search and travel time should mean lower labour expenses, improved order accuracy and maximisation of throughput. Incorporating the horizontal carousel software into an ERP or WCS system will also augment system flow.

Aside from the many operational benefits, one of the main reasons for its increased popularity is the systems adaptability. There are a variety of widths and heights available which allows it to be customised to suit a company’s specific requirements. The ability to double stack opens up the possibility of creating multiple picking zones on separate levels, if installed within mezzanine flooring. The shelves themselves can also be adjusted and there are a number of varying bin heights and widths to choose from.

This flexibility can be implemented to support seasonal periods where higher order quantities are typically more common. For example, if a pod of four horizontal carousels is currently operated by one operator, re-organising this into two double sets makes room for an additional worker. This can be done by simply dividing the pods via the software system, which will in-turn improve speed and of course efficiency.

These type of adjustments become particularly significant for growing organisations, as they can scale up to match customer demand. If they are moving to larger premises, rather than investing in an entirely new system, they can build on-top of the existing process, cutting out additional costs that can prove to be extremely expensive and time consuming.


Of course, this is only a general overview of how a horizontal carousel system works and while we have covered some of the advantages that can be gained, the list of associated benefits are extensive. Installation of the system can also help to increase storage space and allow for a broader and more versatile product range. Perhaps most importantly of all, it will transmit a real-time inventory which will prove invaluable in terms of optimising supply chain productivity.

Changing, or moving to, an automated system is a big step for any business, which means seeing a clear return on your investment is of paramount importance. A horizontal carousel system will not only offer a sustained and reliable service, but create significant improvements to any operation.








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Benefits of Warehouse Automation

Why you Should Consider the Benefits of Automation

Improving efficiency during the manufacturing phase is a never-ending process, stretching back as far as the Industrial Revolution and beyond.  Business owners continue to source ways to reduce costs, while maintaining sustainable selling margins in an increasingly competitive marketplace. There is a fear that the growth of automated systems will eventually lead to the replacement of workers on the production line.  This is especially true for those working in smaller organisations. This does not have to be the case.  The ideal scenario is that machines are used to work alongside and assist current employees, particularly on repetitive tasks that create fatigue.

The food industry in particular has long since been a champion of automated packaging, taking advantage of the exponential leaps in technology that have occurred over the past half a century or so. For businesses thinking of moving across to automated packaging there are two main options available, all of which can be adapted to suit the size and demands of your operation.


This is very much a collaborative process between workers and the machines during the manufacturing process. One of the great benefits of this way of working is the flexibility it offers. A skilled worker has the ability to think of and apply solutions beyond the remit of most machines that have been set to work within strict parameters. Instead of waiting for the machine to address or attempt to correct the issue, they can be solved without losing valuable downtime.

If a production line currently involves the manual strapping of over 50 packages a day, adding a semi-automated machine would lead to noticeable improvements. Not only would it create a faster process and allow for more packages to be strapped, but the consistency of the packaging finish would be a lot higher. Semi-automation also allows room for operators to make adjustments to the packaging if required, rather than leaving it entirely in the hands of the machine.

Fully Automated

Much of the reason why the food and pharmaceutical industries have turned to full automation is because of the strict industry guidelines they must adhere to. A recent study found that humans were responsible for up to 80% of errors that occurred during manufacturing in these sectors.  Aside the huge fines that can be imposed, employee safety is of paramount importance. Automated machinery completely removes this concern for both worker and employer.

As long as regular maintenance is performed, packaging-line automation is not only more reliable but can be adapted to work with a wider range of products. By increasing space within the production line, it will allow for businesses to adapt and grow incrementally, rather than making commitments to larger premises that would then have to be passed onto production costs. A fully automated packaging system will not only lead to a far higher throughput but also more consistency in terms of the packaging presentation.

Of course, budget will no doubt play a key part in deciding which of these solutions are more viable. Updating out-of-date equipment is crucial within any business and striking the right balance between investment and short and long-term return encompasses a number of considerations.

If there is uncertainty about shifting from a manual process straight into one that is fully automated, a good starting point for many is a slow transitional period. Not only will many of the benefits of automation quickly become apparent, but it allows for business owners to have more control about the changeover and to train the existing workforce at a manageable pace. Turning to automation offers a wide range of benefits and is far from as daunting or scary as it may first appear to be.



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The Definition of Intralogistics

Intralogistics means the process of optimizing, integrating, automating, and managing all of the logistical physical flows of supply, production and distribution within a distribution or fulfilment center. By optimising the integration of information processing with the latest material handling technologies and software achieves optimal productivity for both manual and automated systems.

It is not just material handling technologies doing specific tasks like receiving, sorting, picking, and packaging, it’s much more than that. Intralogistics solutions make effective use of sophisticated database and warehouse execution software, which is constantly analysing and optimising the performance of operations. By regulating the system performance at all times ensures that processes are efficient at all times. With an intralogistic system equipment and labor resources are optimised at all times improving complete overall operational productivity.

Intralogistics is an art or philosophy with a top down approach. First starting with an audit and discovery, data, and only then applying the appropriate equipment and software. Smart intralogistic processes can reduce a lot of waste within the process itself.

Intralogistics – Multi-Disciplinary Expertise

Intralogistics requires a multi-disciplinary expertise which encompasses a variety of core expertise such as:

  • Total project management
  • Strategic planning and design
  • Facilities design and automation
  • PLC controls
  • Conveyor and sortation technology
  • Electrical engineering
  • Mechanical engineering
  • Database design with integration
  • Monitoring an analytical reporting

About 2H Storage Solutions

We provide more than an automated material handling systems. 2HSSL always consider intralogisitcs.  Being intralogistics experts, we have implemented solutions in a number of industry sectors from SME to larger distribution centres.  We are aware of the strengths of brands and suppliers and depending on the project requirements appoint accordingly. We offer committed project management and personal support which is the foundation of the success of our logistics projects.

Contact Us

Contact 2HSSL if you wish to implement intralogistics in your distribution or fulfilment centre.
Call us on 01937 585057 or fill out the form below and one of our experts will call you right back:

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Racking your Brains for Storage Solutions

“Trade isn’t about goods. Trade is about information. Goods sit in the warehouse until information moves them”

The benefits of push back pallet racking

Push back pallet rack systems provide a very desirable combination of high density storage and pallet accessibility. The storage density equals that of drive-in pallet rack systems, yet every lane can be accessed at all times. The gravity storage system for bulk goods can be stored on pallets according to the last in first out principle (LIFO). Pallets are pushed back by the next incoming pallet. Any lane can be filled from the aisle without affecting any other adjacent lanes above or below.

Did You Know?

  • The push back racking system also known as dynamic pallet racking is where pallets can be stored two, three, four or up to 10 pallets deep. The pallets are loaded and unloaded from the same aisle reducing truck travel distances and improving efficiency. Once a pallet is picked from the pick face, the rest roll forward automatically under a controlled speed.
  • The system is an ideal solution for warehouses with palletised products and can be used for a wide variety of product types and mixed rotation.
  • The structure is made from certified high-strength steel and has a durable powder coating, meaning that it is rigid, reliable and safe.
  • The height of the racking and the aisle measurements are made to suit specific characteristics of lifting devices, pallet size and the dimensions of the warehouse itself.
  • Push back racking provides all of the density of the drive in system without having to drive into the rack keeping damage to a minimum. It provides the best use of available space and saves time in storage and extraction operations.
  • Push back racking can be located against a wall for a single-sided system where only one side is accessed or in a centre aisle for double sided access.
  • Maximum adaptability to any load type both in terms of weight and volume.
  • Up to 75% increase in storage capacity.
  • Fully demountable and can be relocated at a later date.
  • Fast construction, with minimum disruption.
  • Seamless integration into existing environment.
  • Makes use of existing available vertical space.

What type of Industries use the push back racking system?

There are multiple examples across a wide range of industries such as:

  • Automotive
  • Builders Merchants
  • Electronics
  • Furniture
  • Hardware
  • Pharmaceutical
  • Chemical
  • Food
  • Retail

Installation of pallet racking

Before any installation takes place it always best that a method statement and risk assessment is carried out. The erection of your racking may fall within the Construction Design and Management 2007 regulations therefore, it is important that this is adhered to.

Floor structure

Independent verification is recommended to ensure the floor is of a suitable construction as well as being able to sustain both the weight of the racking and the goods it will hold. In addition it is also important to verify that the floor is suitable to securely floor fix pallet racking, in line with the manufacturers requirements.


It is important to consider the safe use of plant or access equipment as specified by ‘The Provision and Use of Work Equipment Regulations 1998’, and should only be operated by a suitably qualified individual. Any operation should be carried out in line with the appropriate manual handling regulations.

External Pallet Racking

Again, the racking should only be erected externally if the design has first been approved by your pallet racking supplier.

Pallet Racking Assembly

The pallet racking should be levelled to the appropriate SEMA/FEM design code and the uprights floor fixed as specified by the manufacturer. All construction must be assembled in accordance with the manufacturer’s instructions. Please note the importance of the relative guidelines when erecting and levelling pallet racking.








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Warehouse Layouts

Warehouse Layouts and Pallet Racking Design

A1 Rack AWhen designing a warehouse or manufacturing space there is always a requirement for storage equipment usually some form of pallet racking.

Of course once the facility is up and running it is more challenging to make changes, so getting the design correct from the start is important. With that said in some situations it can be beneficial to stage a project if you are unsure how some work flows or processes will develop.

The first thing to consider is what you are going to store it could be six thousand identical pallets or fifty different items but the basic design principles are the same. Just like the old saying a place for everything and everything in its place!

The next thing to consider is access how often will we need to access which items, for some businesses they may need instance access to thousands of items others will be able to archive most of their stored inventory. The most efficient space storage is to block stack everything into a neat pile with no gaps but of course if you need the item at the back at the bottom it means moving everything.

So we work backwards from this for palletised goods the next highest density storage system is drive in pallet racking. This is not suitable if you need access to every pallet so then a narrow aisle APR system offers the next best density.

There are a number of issues to consider building size, fire doors, fork lift truck specification etc. The best way forward is often to get a basic design and then ask a professional storage equipment and warehouse design team to look at your basic design and come up with other ideas.

This allows you to start to understand the design process as the information you will provide on the needs of your business makes you the most important member of the design team for your warehouse layouts and pallet racking design.









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Timber decks for pallet racking

Timber decks for pallet racking 2700mm x 900mm or 2700mm x 1100mm

Timber decks for pallet racking 2700mm x 900mm or 2700mm x 1100mm
Are you looking for timber decks for pallet racking to allow for varying pallet sizes or storing various boxes crate and other items on pallet racking?

Here are 2h Storage solutions we supply tens of thousands of timber decks for pallet racking every year. We offer a wide range of deck options and also provide chipboard and mesh decks in all sizes including pallet flue guard separators for use with in rack and other types of sprinkler systems.

We offer open and closed boarded timber decks in both rough sawn and planned finished options. Made to fit your bay and level sizes with the timber thickness and deck design specifically manufactured for a wide range of loadings from 1000kg timber decks, 2000kg timber decks, 3000kg timber decks and heavy duty specials.

We also offer a supply and install option with weekend working available to help minimise disruption to busy warehouses.

In fact here at 2h Storage we offer a complete pallet racking solution for all types of racking offering products like rack upright guards, anti-collapse mesh, new and used spares. With a full range of services from CAD drawing, site surveys, inventory of storage equipment and identification, designs and build for pallet racking, mezzanine floors, partitioning and a wide selection of warehouse equipment.

So for top quality timber decks fast and cost effective, or any other warehouse and racking requirements call our design team here at 2h Storage Solutions for a FREE of charge site SURVEY.

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