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Classification Methods and Applications of Intelligent Automated Storage Systems: From Selection to Implementation
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Publish Time:
2025-10-05
The intelligent automated warehouse, as the core equipment of modern warehousing, is not “ Single standardized product "Instead, it is subdivided into various types based on dimensions such as 'storage units, automation level, structural design, and industry requirements.' Different types of intelligent automated warehouses vary in…" Space utilization, operational efficiency, cost investment “Significant differences exist, requiring precise matching based on the specific characteristics of the company’s products, business scale, and industry needs. Below is a breakdown of the classification logic and application scenarios to help with selection and implementation.”
I. Classified by Structural Form: Suitable for Different Spaces and Storage Needs
The structural form is the "physical foundation" of the intelligent automated warehouse, determining the way space is utilized, access efficiency, and product compatibility—it is one of the most critical classification dimensions.
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Category Type
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Core structural features
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Advantages
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Applicable Scenarios
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Typical Case
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1. Unit-load Automated Storage and Retrieval System
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At the core is the "independent storage location," with clearly defined shelf zones, where each location corresponds to a single storage unit (pallet/bin), equipped with an aisle stacker crane.
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Flexible storage (supports multiple SKUs), precise access (error ≤ ±5mm), and independent scheduling for each storage location.
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Multi-category, small-to-medium batch storage—for applications like e-commerce (multiple SKUs of small items), pharmaceuticals (multiple batches of medications), and 3C electronics (components/ accessories).
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JD Asia No.1 E-commerce Warehouse (Bin-Type Unit Pallet Storage System, Storing Over 100,000 SKUs)
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2. Through-Type Automated Storage and Retrieval System
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The shelving system features aisle-free layouts, with goods entering from one end and exiting from the other (or both ends for inbound and outbound operations), accessed via shuttles or stackers that move back and forth inside the racks.
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High storage density (30%-50% higher than unit-load systems), ideal for high-volume, continuous inbound and outbound operations.
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Few SKUs, large-volume storage—for fast-moving consumer goods (beverages/food in full cases), cold-chain products (frozen meat/ice cream), and chemicals (bagged raw materials).
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A beverage company's cold-chain warehouse (through-type pallet warehouse, capable of storing 500,000 cases of beverages in a single facility)
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3. Loft-style Automated Storage System
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Utilize steel structures to build multi-level lofts, with each level equipped with shelving and a conveyor system. Elevators or lifts facilitate seamless connections between floors, while the ground floor remains compatible with surface-level operations.
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Fully utilize vertical space (with ceiling heights ranging from 8 to 12 meters), implement tiered, independent management, and seamlessly adapt to irregularly shaped warehouses.
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Small and medium-sized items stored in multiple batches, such as electronic components (resistors/chips), stationery (office supplies), and finished light industrial products (toys/clothing).
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A component warehouse at an electronics factory (a 3-story mezzanine-style bin storage system holding over 200,000 electronic components)
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4. Aisled Stack-Type Automated Storage System
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Centered around "aisles," each aisle is equipped with one stacker crane, and the racking is arranged along both sides of the aisles. The stacker cranes travel back and forth on tracks to store and retrieve goods.
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Highly automated (fully unmanned process), fast access and retrieval speed (150–300 meters per minute), ideal for high-rise storage
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Large-scale, high-turnover storage solutions, such as in manufacturing (automotive parts / home appliances) and logistics hubs (regional distribution centers).
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BYD Automotive Parts Warehouse (20-meter-high aisle stacking warehouse, capable of storing over 30,000 pallets in a single bay)
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5. Mobile Automated Storage and Retrieval System
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The shelves can move horizontally along the rails, allowing storage lanes to be adjusted via "merge/separate aisles," thereby reducing the space occupied by fixed aisles.
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Extremely high storage density (60%-80% improvement over traditional libraries), with space utilization exceeding 90%.
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In space-constrained, low-frequency turnover scenarios, such as archives (historical records), pharmaceuticals (long-term drug storage), and cold storage facilities (for frozen samples).
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A hospital's pharmaceutical cold storage facility (with a mobile racking system, capable of storing 50,000 boxes of medication in a 100㎡ space)
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Automated warehouses typically have a high degree of automation.
II. Classified by Automation Level: Aligning with Enterprise Efficiency and Cost Requirements
The level of automation directly determines the "labor dependency, operational efficiency, and initial investment" of an intelligent automated warehouse. Companies can select the appropriate type based on their scale and budget.
1. Fully Automatic Intelligent Automated Storage and Retrieval System
- Core Features : The entire process requires no manual intervention, as the WCS (Warehouse Control System) seamlessly coordinates stackers, AGVs, sorters, and other equipment to create a closed-loop workflow spanning "receiving - storage - picking - shipping." Equipped with AI algorithms that optimize both routing and inventory management, the system supports 24/7 uninterrupted operations.
- Advantages : Highest efficiency (sorting capacity of 1,500–3,000 pieces/hour), lowest error rate (≤0.01%), and significant reduction in labor costs (only 3–5 operators needed for a 10,000㎡ facility).
- Application scenarios Industries characterized by large scale, high turnover, and significant labor costs—such as e-commerce warehouses (JD.com / Cainiao), automotive factories (Tesla / BYD), and pharmaceutical distribution centers (Sinopharm / Shanghai Pharmaceuticals).
- Case : Cainiao Network's Hangzhou warehouse (fully automated carton-based automated storage and retrieval system) processes 200,000 orders per day, reducing labor costs by 85% compared to traditional warehouses.
2. Semi-Automatic Intelligent Automated Storage System
- Core Features Key processes (such as storage and retrieval, sorting) are automated, while auxiliary tasks (like goods loading/unloading and exception handling) still require human involvement. Equipment configuration is streamlined (e.g., using manual forklifts alongside stackers), and system functionality focuses on basic scheduling.
- Advantages : Initial investment is lower (saving 40%-60% compared to fully automated warehouses), offers high flexibility (allowing for quick manual intervention), and requires minimal operational and maintenance effort.
- Application scenarios Scenarios involving small to medium-sized enterprises with a limited number of SKUs and moderate inventory turnover—such as regional fast-moving consumer goods distributors, mid-sized manufacturing companies (electronics/machinery), and local pharmaceutical distribution centers.
- Case :A beverage distributor in a certain region (using a semi-automatic pallet stereoscopic warehouse) achieved a two-fold increase in storage capacity by employing "stacker cranes + manual loading and unloading." Meanwhile, labor was reduced from 15 to 5 people, while the initial investment cost came in at 3 million yuan (compared to 8 million yuan required for a fully automated warehouse).
3. Manually Assisted Intelligent Automated Warehouse
- Core Features :The shelving features a three-dimensional structure (with heights ranging from 5 to 8 meters), but relies primarily on manual operations—such as using manual forklifts for storage and retrieval—and is equipped only with a basic WMS system for inventory tracking. Automated equipment serves merely as a supplementary tool, like in the case of electronic-label-assisted picking.
- Advantages : Minimal investment required (1–2 million yuan per 1,000㎡), simple operation (no specialized maintenance needed), and well-suited for low-frequency turnover.
- Application scenarios : Small businesses, low-frequency storage scenarios such as quarterly or annual stockpiling, and budget-constrained environments—like small component factories, local food processing plants, and warehouses of offline retail stores.
- Case :A small toy factory (manual-assisted automated warehouse) uses 4-tier shelving combined with manual stackers, increasing storage capacity by 1.5 times compared to a conventional warehouse, while keeping annual operation and maintenance costs at just 50,000 yuan.
The automated warehouse system boasts a high degree of intelligence.
III. Classified by Storage Unit: Suitable for Different Product Forms and Specifications
The storage unit is the "starting point" for the design of an intelligent automated warehouse, and must precisely match the "dimensions, weight, and packaging format" of the goods. It is divided into two main types.
1. Pallet-Type Intelligent Automated Storage System (Load Capacity: 500kg–5 tons)
- Storage unit : Using standard pallets (1200mm × 1000mm / 1100mm × 1100mm) as the basic unit, goods must first be consolidated into palletized loads (e.g., household appliances or automotive components stacked in full cartons on pallets).
- Core Features : Strong load-bearing capacity, suitable for large or heavy items, and offers high storage/access efficiency (single pallet retrieval time: 15–30 seconds).
- Application scenarios ：
- Manufacturing: Automotive engines / tires, home appliances (refrigerators / washing machines), and mechanical components (motors / gears);
- Retail Industry: Fast-moving consumer goods in full cases (mineral water / instant noodles), building materials (tiles / boards), and chemical raw materials (barrel-packed paints / bagged cement).
- Device Compatibility : Aisle stacker, heavy-duty AGV, and forklift AGV.
2. Bin-Type Intelligent Automated Storage System (Load Capacity: 10kg–50kg)
- Storage unit : Using standard containers (such as 600mm × 400mm × 300mm plastic turnover boxes) as the basic unit, it is suitable for handling small to medium-sized items and products with multiple SKUs (e.g., electronic components, pharmaceuticals, snacks).
- Core Features : High storage density (bins can be arranged closely), supports piece-picking, and is compatible with the "goods-to-person" operation model.
- Application scenarios ：
- 3C Electronics: Mobile phone accessories (chargers / earphones), circuit boards / chips;
- Pharmaceuticals: Pharmaceutical packaging boxes (traditional Chinese medicine / Western medicine preparations), medical devices (syringes / masks);
- E-commerce Retail: Apparel (foldable packing boxes), Personal Care Essentials (shampoo / lipstick), Stationery (notebooks / pens).
- Device Compatibility : Four-way shuttles, mini stackers, bin AGVs, and cross-belt sorters.
4. Classified by Functional Purpose: Meeting Industry-Specific Needs
For industries such as pharmaceuticals, cold-chain logistics, and chemical processing—where "special storage requirements" exist (e.g., temperature and humidity control, explosion-proof measures, and traceability)—intelligent automated warehouses must be custom-designed to create specialized subtypes.
1. Smart Automated Cold Chain Warehouse
- Core Customization Equipped with a constant-temperature/low-temperature refrigeration system (temperature range: -30°C to 10°C), anti-condensation devices, low-temperature-resistant shelving (made of stainless steel), and temperature-controlled equipment (with sealed motors). Temperature and humidity are monitored in real time and uploaded to the system.
- Application scenarios : Food (frozen meat / ice cream / fresh produce), pharmaceuticals (vaccines / biologics / blood products).
- Case : Mengniu's cold-chain automated warehouse (-25°C freezer), capable of storing 12,000 ice cream pallets with temperature and humidity fluctuations kept within ±1°C, meets food GMP standards and boasts a storage efficiency three times higher than traditional cold storage facilities.
2. Explosion-Proof Intelligent Automated Storage System
- Core Customization : Utilizing explosion-proof materials (aluminum alloy shelving, explosion-proof motors), non-sparking equipment (explosion-proof AGVs/stackers), and a ventilation system equipped with combustible gas sensors, ensuring compliance with the "Code for Design of Electrical Installations in Hazardous Explosive Environments."
- Application scenarios : Chemicals (paints / alcohol / thinner), hazardous materials (pesticides / disinfectants), and the oil & gas industry (lubricants / fuels).
- Case A hazardous chemical company’s explosion-proof automated warehouse stores 5,000 drums of paint. The equipment meets the Ex d IIB T4 explosion-proof rating and has an impeccable safety record, with outbound efficiency improved by 2.5 times.
3. Intelligent Stereoscopic Pharmaceutical Warehouse
- Core Customization : Meets GMP certification requirements, equipped with a cleanroom system (air purification level of 100,000 grade), RFID-based full traceability (each medication item is linked to a unique label), temperature and humidity monitoring, and dual-person, dual-lock management (for special medications).
- Application scenarios : Pharmaceutical distribution (hospital pharmacies / pharmaceutical companies), pharmaceutical manufacturers (finished drugs / active pharmaceutical ingredients).
- Case : A three-tier hospital pharmacy in Beijing features a state-of-the-art automated storage and retrieval system capable of storing 20,000 types of medications, with a picking error rate as low as 0.005%. Thanks to this advanced system, prescription response time has been reduced from 15 minutes to just 3 minutes, fully complying with pharmaceutical GMP standards.
4. Production-Type Intelligent Automated Storage System (Line-Side Warehouse)
- Core Customization : Real-time integration with the production line MES system, supporting JIT (Just-In-Time) delivery. Shelves are arranged close to the production line (reducing material handling distances), and equipped with a rapid lift mechanism (response time ≤ 2 minutes).
- Application scenarios : Next to manufacturing production lines (automotive / electronics / home appliances), storing raw materials and work-in-progress products.
- Case : Huawei's mobile phone production line's line-side warehouse (material-box-type automated storage system) receives MES production instructions in real time, delivering circuit boards to assembly stations within 3 minutes, reducing production line downtime due to material shortages by 90%.
V. Selection Summary: How to Match "Classification Type" with "Enterprise Needs"
- Examine the product characteristics : Large and heavy goods (palletized), small to medium-sized items with multiple SKUs (bin-based), as well as cold chain / explosion-proof requirements (supported by customized storage solutions);
- Look at the business scale : Large-scale, high turnover (fully automated); medium- to small-scale (semi-automatic); small-scale, low frequency (manual assistance).
- Check the space conditions : Ample space (unit-load / aisle-style), limited space (mobile / mezzanine-style), and irregularly shaped warehouses (mezzanine-style);
- View industry compliance : Pharmaceuticals (GMP-certified warehouse), Chemicals (explosion-proof warehouse), Food (cold-chain warehouse).
For example: E-commerce enterprises (multiple SKUs, high turnover) → Fully automated carton-based unit-load warehouses; automotive plants (heavy goods, JIT requirements) → Fully automated pallet-based aisle stacking warehouses; regional pharmaceutical distributors (small to medium scale, compliance needs) → Semi-automatic, pharmaceutical-specific automated storage and retrieval systems.
Classification is for more precise adaptation.
The classification of intelligent automated warehouses isn’t about “isolated labels,” but rather helps companies narrow down their selection options from various dimensions—whether by structure, level of automation, storage units, or industry applications. At its core, the approach revolves around "prioritizing product demands while aiming for efficiency and cost-effectiveness." As technology continues to evolve, future intelligent automated warehouses will further integrate features such as digital twins (virtual simulations) and AI-driven dynamic optimization. However, the underlying classification logic will still revolve around "adaptability," serving as a crucial guide for companies transitioning from "traditional warehousing" to "smart warehousing."
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