ASRS Installation
Flawless installation of Automated Storage and Retrieval Systems (ASRS) is the foundation of an efficient, high-performing automated warehouse. When you’re investing in ASRS technology—whether it’s Autostore, unit-load, mini-load, carousels, or vertical lift modules (VLMs)—the way it is installed directly affects throughput, picking accuracy, and long-term return on investment.
Nationwide Services provides the specialized expertise in mechanical assembly, material handling equipment, and electrical integration required to install ASRS systems to exact manufacturer specifications. Our focus is on precise, repeatable installation that supports:
- High-density storage and efficient use of vertical space
- Reliable retrieval processes and order picking
- Seamless operation with your warehouse management systems (WMS) and other automated systems
Through years of hands-on ASRS installation work in complex warehouse operations and distribution centers, we’ve fine-tuned additional quality checks that consistently reduce errors, downtime, and commissioning delays. Our team has extensive experience with Autostore and other cutting-edge ASRS solutions designed to help you optimize floor space, streamline inventory management, and support modern warehouse automation strategies.
Recent ASRS Work:
Our ASRS projects range from large-scale Autostore installations to multi-zone systems with mixed technologies:
- 70,600 bins, 9 ports, service platform, 2 additional platforms, 40 robots, 8 seismic towers
- 63,400 bins, 28 ports, service platform, 45 robots, 6 seismic towers
- Assembled 8,310 racks, 439 robots, 143 chargers, 9 IC/QA stations, 9 pick stations, 3 maintenance zones, 4 temp stations, 9 pick/replenish stations, and 2,000’ of fencing
- 34,200 bins, 13 ports, service platform, 54 robots, 10 seismic towers
From high-density storage grids to complex layouts with multiple storage locations, ports, and service platforms, we have the field experience to execute these installations safely and efficiently.
Why Choose Nationwide Services for Your ASRS Installation Project?
Turnkey Installation
Our seasoned professionals deliver meticulous, turnkey installation services for ASRS solutions. We manage the full scope—from receiving and staging components to final mechanical and electrical assembly—so your automated storage and retrieval systems are ready for system integration and go-live.
We routinely work with:
- Autostore and other robotic ASRS solutions
- Mini-load and unit-load systems
- Vertical lift modules (VLMs) and carousels
- Integrated conveyors and storage racks
Whether you’re adding ASRS to an existing warehouse storage footprint or building a new distribution center, our goal is seamless integration with your material handling and warehouse management systems.
Seamless Collaboration
We work closely with your:
- Integrators and automation providers
- In-house engineers and IT teams
- WMS and controls vendors
- Integrated conveyors and storage racks
This coordination ensures all mechanical and electrical components, totes, pallets, controls, and interfaces are correctly installed and ready for programming. The result is an ASRS installation that functions as intended within your broader supply chain and warehouse automation strategy.
Onsite Commissioning Support
Our team provides onsite support during startup and commissioning.
We’re available to:
- Assist with initial testing and adjustments
- Address mechanical or alignment issues that impact throughput
- Support integrators as they connect ASRS systems with WMS and other automated systems
By having experienced ASRS installation specialists onsite, you reduce the risk of extended downtime and help your operation reach target performance levels faster.
Efficient and Reliable Process
We understand that space utilization, labor costs, and project schedules are critical. Our streamlined processes are built to:
- Minimize disruption to ongoing warehousing activities
- Keep the project on schedule and within scope
- Support a fast, predictable ramp-up to full capacity
Our work is focused on long-term operational efficiency—not just getting the system standing, but getting it ready to perform.
Our ASRS Installation Process
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1. Site Preparation and Infrastructure Readiness
We start by thoroughly assessing your facility and storage space to confirm it can support the ASRS system. This includes:
- Floor condition and load capacity
- Clearances, obstructions, and vertical space usag
- Integration points with existing conveyors, racking, and warehouse storage systems
Proper infrastructure and layout planning are the foundation of a stable, high-density ASRS solution.
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2. Mechanical Installation and Structural Assembly
Our experienced team manages:
- Offloading and staging components
- Precise erection of ASRS frameworks, grids, and storage racks
- Installation of service platforms, seismic towers, and safety fencing
Whether the system uses totes, cartons, or pallets to store items, we install the mechanical structure to the tolerances required for reliable movement, stacking, and retrieval.
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3. Electrical Installation
We collaborate with trusted electrical partners for:
- Power distribution to ASRS components
- Control wiring for robots, lifts, drives, chargers, and sensors
- Integration with controls panels, warehouse management systems, and automation networks
Electrical work is done to code and with an eye on long-term reliability, inventory control, and safe operation.
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4. Component Verification
Before commissioning, we meticulously inspect all mechanical and electrical installations.
This includes:
- Verifying robot pathways, bin positions, and storage locations
- Checking clearances for totes, pallets, and handling devices
- Confirming correct installation of chargers, ports, and interfaces
Thorough verification helps streamline commissioning and reduces surprises once software and WMS connections go live.
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5. Commissioning Support and Adjustments
We provide onsite expertise to fine-tune your ASRS for optimal performance:
- Supporting test cycles and order picking simulations
- Addressing mechanical adjustments that impact throughput or alignment
- Working with your automation and controls teams on final tweaks
The goal is a stable, predictable ASRS operation with minimal downtime from first production day forward.
Case Study: Autostore ASRS for a Major Manufacturer
A cutting-edge Automated Storage and Retrieval System (ASRS) project, centered around an Autostore solution, was implemented for Stellantis to dramatically enhance their parts management and operational logistics.
The system includes:
- 70,600 bins for high-density storage
- 9 ergonomic operator ports for efficient order picking and replenishment
- A primary service platform and two additional platforms for operations and maintenance
- A fleet of 40 robots to retrieve and deliver bins, supporting fast order fulfillment
- 8 seismic towers to support structural integrity in seismically sensitive areas
This advanced ASRS installation gives Stellantis a highly efficient, space-saving, and robust storage solution that improves space utilization, reduces labor costs, and supports better inventory management across their supply chain.
FAQs: ASRS Systems and Warehouse Automation
How much does the ASRS system cost?
The cost of an ASRS system varies widely based on storage capacity, system type (Autostore, unit-load, mini-load, VLMs, carousels), integration with WMS, and the complexity of your warehouse operations. Smaller systems can start in the lower six figures, while large, multi-zone installations in a distribution center may reach well into the millions. The right design balances storage space, throughput, and long-term return on investment.
How much does a mini-load ASRS system cost?
A mini-load ASRS typically costs less than large unit-load or pallet-based systems but still depends on rack height, number of aisles, shuttle or crane design, and storage locations required. It’s often a cost-effective choice for cartons and totes when you need dense storage and higher picking accuracy without committing to a full-scale system.
What factors should I consider when hiring a machinery moving and installation service?
Key considerations include:
- The size, weight, and complexity of the industrial machinery
- Impact on production lines and scheduling to reduce downtime
- Space constraints, access points, and staging areas
- Safety requirements and OSHA compliance
- Coordination with your general contractor, engineers, and other providers
We work with you up front to address all of these factors so the moving project runs smoothly.
How much does it cost to automate a warehouse?
The cost to automate a warehouse depends on the mix of automated systems you implement—ASRS solutions, conveyors, robotics, vertical lift modules, WMS, and more. A phased approach is common: starting with ASRS in a high-volume area and then expanding into other warehouse automation solutions as your needs grow.
What are the benefits of installing an ASRS in my warehouse?
Installing an ASRS in your warehouse can:
- Increase storage capacity and space utilization through high-density storage
- Improve inventory management and inventory control
- Raise throughput and picking accuracy in order fulfillment
- Reduce labor costs and ergonomic strain with more ergonomic workstations
- Help streamline warehouse operations and support long-term scalability
With the right ASRS solutions, many operations see measurable improvements in both productivity and overall return on investment.
Planning an ASRS Installation?
If you’re evaluating ASRS technology or ready to move forward with an installation, Nationwide Services can help you execute with confidence. From mechanical and electrical assembly to onsite commissioning support, we provide the experience and structure you need for a successful project.