Home›Storage›Carousel Systems

Carousel Systems

Carousel systems use rotating shelves or bins that automatically deliver items to stationary operators, improving picking productivity and space utilization through goods-to-person automation.

Carousel Systems Overview

🎠

Carousel Types

•
Horizontal Carousels
Rotate on horizontal plane
•
Vertical Carousels
Rotate on vertical plane
•
Pod Configuration
2-3 units per operator
•
Batch Picking
Multiple orders simultaneously

🏭

Applications

•
Manufacturing
Parts & assembly
•
Distribution
Order fulfillment
•
Retail
Back-room storage
•
Healthcare
Pharmacy automation

✨

Key Benefits

•
60-75% Space Savings
vs. static shelving
•
2-3x Productivity
Picking improvement
•
99.9%+ Accuracy
Order fulfillment
•
Ergonomic Access
Reduced strain

⚡

Performance

•
300-600 picks/hour
Per operator
•
10-40 seconds
Average retrieval time
•
90% Travel Reduction
Operator movement
•
99%+ Uptime
System reliability

💰

Investment

•
Horizontal: $25-50K
Per unit
•
Vertical: $40-80K
Per unit
•
Pod System: $75-150K
2-3 units
•
ROI: 1-2 years
Typical payback

🚀

Future Trends

•
Robotic Picking
Automated arms
•
IoT Analytics
Real-time monitoring
•
AI Optimization
Smart slotting
•
Energy Efficiency
Sustainable design

80-120

ft/min rotation speed

±0.25"

positioning accuracy

95%

search time eliminated

40-60%

labor reduction

How Carousel Systems Work

Horizontal carousels consist of shelves or bins mounted on a chain-driven track that rotates horizontally around an oval path. When an item is requested, the carousel rotates to position the appropriate shelf at the pick window where the operator stands. Rotation speeds of 60-120 feet per minute enable rapid item delivery, with typical retrieval times of 10-30 seconds depending on item location. Multiple carousels can be integrated into pods where one operator picks from 2-4 carousels simultaneously, maximizing productivity by minimizing wait time.

Vertical carousels use carriers mounted on chains that rotate vertically, similar to a Ferris wheel. The system rotates to deliver the requested carrier to an access opening at a comfortable working height. Adjustable carrier heights (typically 6-24 inches) accommodate varying product dimensions, with the control system automatically optimizing storage positions to minimize wasted vertical space. Rotation speeds of 80-150 feet per minute provide rapid access to stored items.

Control software manages carousel rotation, optimizes pick sequences, and integrates with warehouse management systems. Batch picking strategies group multiple picks to minimize rotation cycles, while intelligent sequencing delivers items in optimal order for order fulfillment. Inventory tracking maintains real-time records of item locations, supporting accurate inventory management and cycle counting.

Key Benefits

Productivity improvements of 2-3x result from eliminating worker travel time and presenting items at ergonomic heights. Workers remain stationary while carousels deliver items, achieving pick rates of 100-250+ lines per hour depending on order complexity. Reduced fatigue from eliminating walking and reaching improves worker satisfaction and reduces injury risks.

Space savings of 50-70% come from high-density storage and elimination of aisles. Horizontal carousels utilize ceiling height through multi-level installations, while vertical carousels maximize vertical space in compact footprints. A single vertical carousel occupying 15-25 square feet can replace 100-200 square feet of shelving.

Inventory accuracy exceeds 99% through controlled access and automated tracking. Secure storage with access control prevents unauthorized removal, valuable for high-value items. Environmental protection with optional enclosures protects sensitive items from dust or contamination.

Economical automation provides goods-to-person benefits at lower capital costs than AS/RS or shuttle systems. Simple installation requires minimal facility modifications, with systems operational in days rather than months. Scalability allows starting with one carousel and adding more as needs grow.

Common Applications

Order fulfillment operations use carousel systems for picking small parts, components, or products for customer orders. Batch picking for multiple orders improves efficiency. Multi-carousel pods maximize throughput by keeping operators continuously productive.

Spare parts distribution in automotive, industrial, and electronics sectors leverages carousels for managing thousands of SKUs. Rapid retrieval enables quick order fulfillment. Inventory tracking supports procurement and planning.

Manufacturing employs carousels for component storage and kitting near production lines. Just-in-time delivery of parts reduces work-in-process inventory. Tool cribs manage tools with automated tracking and controlled access.

Healthcare and pharmacy operations use carousels for medication storage and dispensing. Controlled access and audit trails support regulatory compliance. Secure storage prevents theft of controlled substances.

Electronics assembly uses carousels for component storage at assembly workstations. Rapid access to thousands of component types supports diverse product assembly. Inventory tracking ensures adequate stock levels.

Implementation Considerations

Horizontal carousel sizing considers length (typically 10-60 feet), height (6-10 feet), and depth (12-30 inches per side). Capacity ranges from 200-2,000 cubic feet per carousel. Floor space of 100-600 square feet per carousel plus operator area.

Vertical carousel sizing considers height (8-40 feet), width (6-12 feet), and depth (2-4 feet). Capacity ranges from 100-1,000 cubic feet per carousel. Floor space of 15-50 square feet per carousel.

Capital investment of $25K-100K per carousel with typical payback of 2-3 years through labor savings and space efficiency. Installation requires minimal facility modifications, with systems operational in 1-2 weeks.

Integration with picking stations, inventory systems, and facility infrastructure. Pick-to-light or voice picking systems improve accuracy and speed. WMS integration provides real-time inventory visibility and automated replenishment.

Best Practices

Slotting optimization places high-velocity items in the most accessible positions (near pick window for horizontal, middle heights for vertical) to minimize rotation time. ABC analysis guides placement. Dynamic slotting adjusts locations based on velocity changes.

Batch picking groups orders to minimize carousel rotations. Multi-carousel pods (2-4 carousels per operator) maximize productivity by minimizing wait time. Intelligent sequencing delivers items in optimal order.

Preventive maintenance includes monthly inspections, quarterly lubrication, and annual professional service. Spare parts inventory enables rapid repairs. Well-maintained carousels operate reliably for 15-20 years.

Ergonomic workstation design with proper lighting, adjustable work surfaces, and anti-fatigue mats maximizes operator comfort and productivity. Clear labeling and organized storage within carriers or shelves improve pick accuracy.

Measuring Success

Key metrics include picks per hour (target 100-250+), space savings (square feet freed), inventory accuracy (target 99%+), and system uptime (target 98%+). ROI materializes over 2-3 years through labor savings and space efficiency. Productivity improvements and reduced travel time validate the investment.

By implementing carousel systems with attention to sizing, slotting optimization, and workstation design, facilities achieve significant productivity improvements and space savings for small to medium SKU count operations at economical investment levels.