Miniload AS/RS

The KAPELOU Miniload AS/RS is an automated storage and retrieval system designed to address the challenges of maximum storage density and efficient space utilization within existing warehouse infrastructure.

Key advantages of the solution:

• high picking throughput – powered by the Goods-to-Person principle, required totes and containers are automatically delivered to the operator at a consistent speed – even during peak periods;
• high accuracy and 24/7 operational stability – automated replenishment and retrieval cycles significantly reduce human involvement, minimizing picking errors;
• real-time inventory control – every container movement is recorded by the control system, improving inventory accuracy, reducing search time;
• significantly increased storage density within the existing footprint – retrieval in ultra-narrow aisles combined with full utilization of vertical space;
• lower operating costs – faster retrieval, reduced unnecessary movements, and lower manual labor requirements;
• faster order fulfillment and improved customer experience;
• scalable architecture for business growth – the system can be expanded by adding additional storage locations with minimal impact on ongoing operations;
• improved personnel safety – operators work in controlled stations while load movements are handled by the system;
• engineered to match your specific warehouse layout and load characteristics;
• energy efficiency – low energy consumption and the ability to operate in fully automated warehouses without permanent lighting;
• fast staff onboarding – an intuitive user interface enables operators to work efficiently with the automatic storage system for light goods from the first days of operation.

KAPELOU Miniload AS/RS is suited for warehouses planning future growth, handling a wide SKU range, and requiring effective automation without sacrificing flexibility.

Miniload AS/RS for boxes is an automated storage and retrieval system, enabling the automatic transport of loads to and from the storage area. A typical automatic small goods transport system configuration includes a rack structure, a stacker crane, replenishment and picking stations, and warehouse control software (WCS) that coordinates automated small parts storage and retrieval processes in real time. The KAPELOU Miniload stacker crane control system ensures precise positioning, safe operation, and integration of the equipment into the overall automated warehouse environment.

The Miniload stacker crane travels along the central aisle between the racking, while the load carriage equipped with a handling device moves vertically along the mast to the required storage level. The load handling device then retrieves a container from a storage location or places it into the assigned position. Once the cycle is completed, the crane returns to the end of the aisle, where the load is transferred to a conveyor or picking station for further processing – or the crane immediately proceeds with the next task by picking up another load.

The automatic Miniload warehouse can be equipped with two types of load handling devices, allowing the automatic warehouse system to balance storage density and access speed:

• Single-Deep load handling device handles one tote or container per cycle and is optimized for fast access and high picking frequency;
• Double-Deep load handling device handles loads stored two positions deep (2 containers), increasing storage density and space utilization without expanding the warehouse footprint.

The choice of load handling device is determined by SKU profile, access frequency, and throughput requirements. Each automatic Miniload system is engineered to match the customer’s actual operational model.

At KAPELOU’s own warehouse, an automated Miniload logistics has been implemented to ensure fast and precise access to the required SKUs. The storage area handles nearly 6,000 SKUs of small components, many of which are visually similar, with a single tray containing up to 8 different item types.

The project significantly accelerated item retrieval and improved picking accuracy. The Miniload automated storage and retrieval system retrieves products with stable, predictable throughput and zero picking errors.

The crane-based Miniload logistics optimizes warehouse operations by:

• automatically delivering the required tray with the correct SKUs directly from the storage area, eliminating visual search;
• reducing dependency on product knowledge and minimizing the human factor;
• compensating for labor shortages by automating key material-handling operations.

As a result, warehouse logistics operate in a stable and predictable manner. The crane-based automated Miniload system ensures fast, consistent small-item handling with high accuracy and minimal human involvement.

A traditional warehouse relies on manual handling and requires personnel to move between storage, picking, and order preparation areas. In this model, speed, accuracy, and throughput depend on workforce availability, making planning and scaling difficult.

Miniload AS/RS operates as a single system, where product movement is driven by process logic. Miniload stacker cranes automate storage and retrieval operations, provide fast access to small loads, and enable a controlled material flow.

Advantages of an automated warehouse with Mini-load AS/RS:

• warehouse process optimization – containers and trays move automatically according to predefined logic, without chaotic personnel movement;
• predictable operational performance;
• higher workforce productivity through automation of routine tasks;
• reduced impact of the human factor;
• reduced labor costs.

A Mini-load AS/RS delivers operational stability, scalability, and long-term efficiency.