Automated high-bay warehouse (HRL)

Efficient use of space with large load carriers

Do you need large storage capacities? High-bay warehouses enable optimum use of space and offer maximum storage capacity with a height of 12 to 45 meters, as the available floor space can be used optimally and effectively.

Automated pallet warehouses ensure efficient goods storage and distribution - even for heavy and large-volume goods. With the help of complex racking systems, more than one hundred thousand pallet spaces can be realized.

An automated high-bay warehouse is the right solution, especially for enormous volumes of goods. A high-bay warehouse from Unitechnik guarantees optimum use of space, fast and direct access, high process reliability and optimum storage conditions at heights of up to 45 meters.

Both autonomous vehicles and conventional conveyor technology can be used to connect the high-bay warehouse with other intralogistics components.

Advantages of an automated high-bay warehouse

Efficient use of space

Low personnel requirements

High
process reliability

up to
45m high

Your contact persons

Michael Huhn

Head of Sales
Authorized signatory

T +49 2261 987-518
E-Mail | vCard

M. Yusuf Kaya

Key Account Manager
Logistics Systems

T +49 2261 987-524
E-Mail | vCard

Andreas Klee

Key Account Manager
Logistics Systems

T +49 2261 987-525
E-Mail | vCard

Christian Mertens

Key Account Manager
Logistics Systems

T +49 2261 987-502
E-Mail | vCard

From the selection of manufacturers to complete integration

  • Conceptual design
  • Component and manufacturer selection
  • Realization from a single source
  • Ramp-up management, training and service

Control of logistics processes

  • UniWare warehouse management system ensures maximum efficiency
  • Optimization of existing processes
  • Integration of all new processes into the logistics processes
  • Maximum process reliability and stability
  • UniWare: warehouse management, material flow control and system visualization in one system. You can find more information here

 

Automated high-bay warehouse with shuttle or stacker crane

HRL with shuttles

  • Large number of vehicles within the racking system
  • Flexibly adaptable to building geometry
  • Level and aisle changes possible
  • Scalability of performance through additional shuttles
  • Multi-deep storage
  • Focus: storage and sorting

HBW with storage and retrieval machine(s)

  • Rail-guided, automatic vehicle for transportation
  • Single or double load handling attachment
  • Multi-deep storage
  • Focus: Storage

Silo construction vs in-house

Silo construction:

  • Storage system as load-bearing substructure for roof and façade, no separate hall required
  • Sequence:
    1. Floor slab
    2. Shelving system
    3. Wall and roof panels
    4. Installation of the appliances
  • Can be used as refrigerated or deep-freeze storage thanks to insulated panels
  • Useful from a storage height of approx. 20 meters: We can advise you!

In-house:

  • Free-standing installation in an existing hall
  • Use of the existing hall structure for the storage system
  • Can be flexibly integrated into existing building structures
  • Ideal for retrofitting and expanding existing storage capacities
  • Tailor-made solutions for individual storage requirements: We can advise you!

Automated high-bay warehouses - The system comparison

RBGShuttle
Max. height45 m30 m
PerformanceMediumHigh
Limiting
Power factor
RBG powerSiphon power
ScalabilityLowHigh
Space utilizationHighHigh
Temperature rangeNormal, Cool, TKNormal, Cool, Freezer

 

Unitechnik takes responsibility from A to Z

Spare parts logistics center at CLAAS in Hamm Uentrop. As general contractor, Unitechnik was responsible for the high-bay warehouse, conveyor technology and order picking.

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Automatisches Hochregallager für CLAAS
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FAQ: High bay warehouse

High-bay storage systems offer numerous advantages - they offer the possibility of using racking systems with a height of up to 45 meters. This means that the available floor space can be optimally utilized. Large storage capacities can be realized with a high-bay warehouse.

Fully automated high-bay warehouse systems guarantee fast and direct access to all items or products. Thanks to the warehouse management system and automation, a smooth picking process (goods-to-person) can be realized with high process speed and simultaneous safety.

In addition, automation leads to shorter throughput times and thus to increased warehouse efficiency.

The different components of a storage system always depend on your requirements. Unitechnik will work with you to select the most suitable components based on your requirements in order to design your high-bay storage system efficiently.

We work with you to determine a storage system that is optimally adapted to the storage of your items or products. In this context, we work out the shelf heights for your high-bay warehouse that are individually tailored to your requirements.

Shuttle systems consist of autonomous transport trolleys that move along the rack levels and transport goods between storage locations and transfer stations. Several shuttles can operate simultaneously in different aisles, which significantly speeds up storage and retrieval processes. Thanks to their modular design, shuttles can be scaled flexibly and used particularly efficiently in dynamic logistics environments.

Storage and retrieval machines (SRMs) are ideal for warehouses with high rack structures, large-volume pallets and high load capacities. They move along rails through the rows of racks and enable precise storage and retrieval with minimal space requirements. They offer a reliable solution, especially for high turnover rates and limited space.

What impact does automation have on the operating costs of a warehouse?

Although automated high-bay warehouses require a higher initial investment, they lead to significantly lower operating costs in the long term. This is due to the reduced personnel costs, optimized processes and more efficient use of space and energy. Manual warehouses, on the other hand, incur permanent personnel and operating costs, which grow continuously as warehouse turnover increases.

The combination unites the strengths of both systems: the high load capacity and reach height of the SRMs with the speed and flexibility of the shuttles. The result is optimum space utilization, short throughput times and high scalability - especially with growing storage requirements.

When considering whether a warehouse should be built in a silo or in-house, the current conditions and the requirements for the storage system must also be taken into account.
The space requirement is of course an important point of reference here. From a storage height of 20 meters, for example, silo construction can make sense.
Unitechnik will advise you on finding the right solution for your company.

It is important to find the right system solution for your high-bay warehouse from the many different manufacturers.
Unitechnik provides expert and objective advice when selecting suppliers in order to implement an intelligent overall system that is optimally connected to the functional areas of your logistics center.

Single-deep, double-deep or multi-deep storage and retrieval - it's a question of space utilization versus speed. We will work with you to find the right storage system to make your high-bay warehouse as efficient as possible.

The question of shelf heights is closely related to the products or items you store. Different compartment heights increase your flexibility.

The scalability of a high-bay warehouse is a decisive factor in growing storage requirements. While manual warehouses require additional manpower, an automated high-bay warehouse can be scaled simply by using additional shuttles or enhancements to the control software. This ensures that the system remains efficient and future-proof even as throughput increases.

Yes, automated high-bay warehouses are particularly space-saving. Thanks to high rack structures and compact storage and retrieval technology, they enable maximum space utilization. In contrast, manual systems require larger traffic areas and offer a lower storage density - a clear advantage of automation where space is limited.

After the pallet arrives, an automatic contour check and identification via barcode or RFID takes place. The stored goods are then transported to the pre-zone via conveyor technology. There, storage and retrieval machines or shuttles take over the space-optimized storage. During retrieval, the system makes the goods available at the right time and intelligently coordinates orders to minimize routes and avoid bottlenecks.

The control software coordinates the entire warehouse processes - from order prioritization to path optimization of the transport technology. It guarantees a high level of process reliability, reduces errors and ensures optimum space utilization through dynamic storage strategies.

References and case studies for automated high-bay warehouses

Ethiopian Airlines

Planning and realization of an airfreight center for 600,000 t of freight per year, partly refrigerated, automated high-bay warehouse for 1000 ULDs, 4ETVs, man. Warehouse for 8,500 pallets

Leopold Kostal

4-aisle pallet high-bay warehouse with 7,000 storage locations. The pallet conveyor technology supplies 10 picking stations. Picking via SAP. Storage and retrieval takes place on both sides of the warehouse aisles.

Worth knowing

High-bay warehouse planning

A good planning process needs clear and transparent structures - as in our proven 3-phase model. We would be happy to support you in planning your high-bay warehouse as an integral part of your internal logistics.

Find out more about planning your high-bay warehouse here

Automated high-bay warehouse Costs

Would you like to know how much a warehouse costs? No problem, use our new warehouse planning tool. Enter the number of storage locations you require and we will compare two alternative solutions with space and personnel requirements as well as the investment budget. Try it out - quickly and anonymously.

Click here for the warehouse planning tool

High-bay warehouse: Videos

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42 m hohes Tiefkühllager in Rumänien
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Europe's highest deep-freeze high-bay warehouse for the Romanian company Macromex

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Montage des Hochragallagers für CLAAS im Zeitraffer
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Assembly of the high-bay warehouse for CLAAS in fast motion

Free download: The 7 pitfalls when building a high-bay warehouse

We have been implementing logistics projects as a general contractor for over 20 years. In the process, we have repeatedly noticed things that hinder the success of projects. We have described seven pitfalls in a PDF.

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Construction and statics of high-bay warehouses

Design variants of high-bay warehouses

The design of a high-bay warehouse significantly influences its stability, costs and utilization options. As explained above, there are two basic design variants: silo construction and free-standing high-bay warehouses.

In silo construction, the racking itself forms the load-bearing structure for the roof and walls. This results in a particularly space-saving and economical solution that enables high load-bearing capacities. This construction method is particularly suitable for large-volume high-bay warehouses with high demands on space utilization and statics.

Free-standing high-bay warehouses, on the other hand, consist of racking systems within a separate building. This variant offers more flexibility, as the warehouse can be planned and expanded independently of the building envelope. It is often used when existing storage areas are to be modernized or extended.

The decision between the two construction methods depends on factors such as load capacity, construction costs and long-term scalability. While the silo design offers maximum space utilization, the free-standing design allows for greater adaptability.

High-bay warehouse made of steel - advantages in stability and durability

Steel is the preferred material for high-bay warehouses as it offers high load-bearing capacity, stability and durability. Its resistance to mechanical loads and environmental influences makes it particularly suitable for warehouses with high rack structures and intensive use.

Another advantage of steel is its flexibility in design. Individually adapted racking systems can be implemented for various industry requirements - whether for pallet storage, deep-freeze storage or hazardous materials storage. Steel also enables sustainable use as it is fully recyclable.

Thanks to precise manufacturing and modern coating techniques, high-bay warehouses made of steel are particularly low-maintenance. They offer long-term investment security and meet the highest safety requirements in industrial use.

Static requirements and DIN standards for high-bay warehouses

The construction of a high-bay warehouse is subject to strict static requirements and DIN standards to ensure safety and stability. It is particularly important to calculate the loads - both dead weight and dynamic loads due to goods movement, wind loads or earthquakes.

DIN EN 15512 specifies the requirements for the load-bearing capacity and design of shelving systems. Other relevant standards such as DIN EN 15620 (dimensional tolerances), DIN EN 15635 (inspection & maintenance) and DIN EN 1993 (steel structures) define technical standards for high-bay warehouses.

In addition to standard-compliant planning, regular inspections play a central role. Structural verification, annual safety inspections and professional maintenance ensure long-term stability and prevent accidents or material fatigue during warehouse operation.

Customized solutions for every storage requirement

High-bay warehouses for different industries and requirements

Deep-freeze high-bay warehouse - challenges at temperatures below zero

Deep-freeze high-bay warehouses have to withstand extreme conditions. Temperatures as low as -30 °C require specially designed racking structures, insulated storage areas and cold-resistant technology.

Automated systems play a decisive role here: storage and retrieval machines and shuttles minimize the use of personnel in icy environments and increase efficiency. At the same time, materials are required that function reliably even at low temperatures.

A particular challenge is the icing up of conveyor technology and sensors. Intelligent control systems and regular maintenance prevent breakdowns and ensure smooth operation. Companies benefit from a reliable storage solution that combines energy efficiency with maximum availability of goods.

Pallet and pallet cage storage for different goods requirements

High-bay warehouses must be able to adapt flexibly to different types of goods and storage formats. While pallet warehouses are ideal for large-volume goods such as raw materials or finished goods, pallet cage warehouses offer a stable and stackable solution for heavier or bulky products.

Pallet warehouses rely on high-performance storage and retrieval machines that move heavy loads efficiently. They are particularly suitable for sectors such as industry, food production or logistics centers.

Mesh box warehouses use similar racking technology, but also benefit from the stable construction of the boxes, which are particularly suitable for metallic or heavy components - for example in the automotive or mechanical engineering industries.

A well thought-out integration of both types of storage allows material flows to be optimized, loading units to be designed flexibly and storage capacity to be utilized efficiently.

Special solutions for hazardous substances and sensitive products

Special safety requirements apply to the storage of hazardous substances and sensitive products. High-bay warehouses for chemicals, medicines or electronics must comply with both legal regulations and strict quality standards.

Explosion protection, fire protection measures and special ventilation systems play a key role for hazardous substances. Sump trays, closed storage units and temperature-controlled areas ensure maximum safety.

Sensitive products such as foodstuffs or electronic components require precise control of temperature and humidity. Modern high-bay warehouses integrate climate-controlled zones and low-vibration storage technologies to ensure product quality and shelf life.

Specialized solutions enable companies to comply with legal requirements while implementing efficient, automated storage processes.

Perfect coordination between warehouse, transportation and order picking

High-bay warehouse and conveyor technology - seamless integration into logistics

Efficient integration of conveyor technology and high-bay warehouses is crucial for smooth material flows. Various interfaces are relevant here:

  • Incoming goods: Automatic conveyor belts and lifting systems take care of storage.
  • Rack connection: Conveyor lines transport goods directly to storage and retrieval machines or shuttle systems.
  • Outgoing goods: Sorting systems and buffer areas optimize outgoing goods transport.

Modern control systems ensure that conveyor technology and warehouse management work synchronously. This avoids congestion and delays, while the warehouse processes adapt to actual demand.

Automated order picking increases efficiency and reduces error rates. Modern high-bay warehouses rely on various technologies:

  • Pick-by-Light / Pick-by-Voice - Visual or acoustic instructions for employees.
  • Shuttle systems & storage and retrieval machines - transport goods directly to picking stations.
  • Robot-supported gripper systems - Fully automated picking without human intervention.

The right combination of these systems makes order picking faster, error-free and cost-efficient - a key advantage for e-commerce, food or pharmaceutical logistics.

The pre-zone is the link between the warehouse and dispatch. This is where all goods movements come together before they are transferred to the next logistics step.

  • Buffer zones & sequencing: Optimum order of retrieval for efficient processing.
  • Sorting & distribution systems: Automatic identification via barcode or RFID.
  • Shipping preparation: Palletizing, labelling and consolidation of goods.

Efficient conveyor technology in the pre-zone reduces throughput times and ensures maximum process reliability. This means that orders reach their destination faster and more reliably.

Digital control for smooth warehouse operations

Important software solutions for controlling a high-bay warehouse

Warehouse management systems (WMS) and their functions

With our UniWare warehouse management system, we control high-bay warehouses efficiently and ensure a smooth material flow. UniWare combines inventory management, order planning and material flow control in one powerful platform.

Our software offers:

  • Precise inventory management in real time to ensure full transparency.
  • Optimized order planning that speeds up picking and putaway processes.
  • Integrated material flow control that intelligently coordinates stacker cranes, shuttles and conveyor technology.
  • System visualization that displays the warehouse layout in real time and identifies optimization potential.

Thanks to its modular structure, UniWare can be flexibly adapted to individual requirements. With AI-supported functions, such as automated replenishment strategies and intelligent package optimization, we improve efficiency and reduce operating costs.

Learn more about UniWare

Connection to ERP systems for an end-to-end logistics chain

Linking a high-bay warehouse to an ERP system creates a continuous and transparent logistics chain. All warehouse movements are synchronized with the company processes in real time.

Advantages of the ERP connection:

  • Automatic order processing through direct communication with the purchasing department.
  • Real-time updates of stocks, production orders and shipping status.
  • Optimized capacity planning through coordinated material flows.

SAP, Microsoft Dynamics or other ERP systems can be connected to the warehouse management system via interfaces. This creates an integrated logistics network that reduces manual processes, minimizes errors and speeds up the supply chain.

Data analysis and optimization through modern software solutions

Modern high-bay warehouses are increasingly relying on big data and AI-supported analyses to optimize warehouse processes. Smart algorithms can be used to precisely evaluate stock levels, goods movements and replenishment processes.

Optimization potential through data analysis:

  • Predictive analytics - predicting bottlenecks and seasonal fluctuations.
  • Performance monitoring - analysis of throughput rates and warehouse utilization.
  • Automated optimization - dynamic adjustment of warehouse strategies.

By using cloud technologies and IoT, companies can monitor their warehouse in real time and identify bottlenecks at an early stage. The result: higher efficiency, lower operating costs and maximum utilization of warehouse capacity.

Step by step to the optimum storage solution

Planning and implementing a new high-bay warehouse - what is important

The successful implementation of a high-bay warehouse begins with a detailed analysis of the individual storage requirements. We take factors such as the type of stored goods, turnover rate and future expansion options into account in order to develop a tailor-made solution.

A key aspect is the optimal use of storage capacity. Through precise planning, we ensure that the available space is used efficiently and that work processes mesh smoothly.

Investment costs vs. long-term savings - A high-bay warehouse is a long-term investment. We help companies to weigh up the initial costs of technology and infrastructure with the long-term benefits such as reduced personnel costs, increased efficiency and greater process reliability.

With our proven three-phase plan in logistics consulting, we support companies in optimizing their intralogistics economically and future-proof.

Logistics consulting from Unitechnik

The future of high-bay warehouses - trends and innovations

Artificial intelligence in warehouse management

Artificial intelligence (AI) is revolutionizing warehouse management through automated data analysis and intelligent process control. AI algorithms optimize stock levels, reduce bottlenecks and improve the route planning of storage and retrieval machines and shuttles.

Using predictive analytics, the system recognizes fluctuations in demand at an early stage and automatically adjusts storage strategies. In addition, self-learning algorithms enable continuous improvement of material flows.

Companies benefit from greater efficiency, lower costs and a faster response to market changes - a decisive advantage in modern logistics.

Sustainable high-bay warehouses: energy efficiency and resource-saving concepts

Sustainability is playing an increasingly important role in warehouse logistics. Energy-efficient storage and retrieval machines, intelligent lighting systems and the use of renewable energies significantly reduce energy consumption.

In addition, materials for shelving constructions are increasingly recyclable or made from sustainable raw materials. The optimization of warehouse processes also contributes to sustainability - through shorter transport routes and a reduction in empty runs.

Modern high-bay warehouses rely on climate-friendly solutions to reduce CO₂ emissions and save costs in the long term.

Robotics and autonomous systems for intralogistics

Robot-assisted systems play a decisive role in modern intralogistics. At Unitechnik, we rely on innovative solutions such as palletizing and depalletizing robots, picking robots and autonomous mobile robots (AMR) to increase efficiency and precision in warehouse and material flow processes.

Our palletizing and depalletizing robots optimize the stacking and unloading of pallets, while picking robots remove items directly from shelves or containers and transfer them precisely to target stations. The integration of AMR enables flexible and autonomous transportation of goods within the warehouse.

By using these technologies, we increase productivity and enable a flexible response to future challenges. Our solutions can be seamlessly integrated into existing systems and offer a high level of scalability.

Unitechnik robotic solutions