The situation: A mid-sized distribution center is struggling to keep up with rising order volumes. Forklift traffic clogs narrow aisles, operators spend hours searching for SKUs, and inventory errors lead to costly shipping mistakes. Labor shortages only make matters worse—overtime is skyrocketing, and expansion plans are stalled because there’s simply no room to grow.

ASRS systems maximize vertical and horizontal space, often reducing facility footprint by 30–60%. This can defer costly building expansions, skyrocketing operating costs, and lower real estate costs.

These challenges aren’t unique. Across manufacturing and distribution, companies face mounting pressure to do more with less space, labor, and margin for error. That’s where an ASRS system (Automated Storage and Retrieval System) becomes a game-changer. By automating storage and retrieval, ASRS solutions eliminate bottlenecks, maximize vertical space, and deliver goods directly to the operator—boosting throughput, accuracy, and profitability.

In this article, we’ll explore the different types of ASRS systems, their benefits, and why Muratec USA is the trusted partner for automation solutions that transform supply chains worldwide.

What Is an ASRS System?

An ASRS system is a computer-controlled material handling solution that automatically stores and retrieves items from defined locations. These systems integrate storage structures (racking or modules), load handling devices (cranes, shuttles, carousels, or lifts), and software for inventory control and task execution.

ASRS systems are ideal for environments where inventory accuracy, speed, and space efficiency are critical—think manufacturing kitting lines, component storage, finished goods, cold chain, e-commerce picking, and spare parts. By bringing goods to the operator (or directly to the next process), ASRS minimizes walking, searching, and manual touches to shorten cycle times and improve throughput.

Types of ASRS Systems

Selecting the right ASRS system starts with understanding your material movement, process improvement goals, and constraints. Each type offers unique advantages based on load size, throughput requirements, and available space. Here’s a closer look:

1) Unit-Load ASRS
Unit-load systems handle palletized or large containers using automated cranes in high-bay racking.

  • Best for: Heavy, bulky items; high-density pallet storage; buffer storage between production and shipping.
  • Benefits: Space savings through tall, narrow aisles; inventory accuracy; reliable, repeatable handling; reduced forklift traffic and risk.
  • Use Case Example: A manufacturer storing finished goods in a high-bay warehouse can reduce floor space by up to 60% while improving order accuracy.

2) Mini-Load ASRS
Mini-load systems are designed for smaller loads totes, cases or trays, using lightweight cranes for rapid retrieval.

The Muratec Mini-Load UX Crane is specifically designed for loads weighing less than 110 lbs, and handles totes, crates, and free-size cases. 

  • Best for: Small parts, components, e-commerce order picking, kitting.
  • Benefits: High-speed picking, excellent slotting, tight footprint, improved ergonomics via goods-to-person workflows.
  • Use Case Example: Electronics assembly plants use mini-load ASRS to feed production lines with precise component kits, reducing downtime.

3) Shuttle-Based ASRS
Shuttle systems use autonomous carts moving along storage levels to transfer cases, totes or trays to lifts and pick stations.

  • Best for: High throughput with frequent picks/puts, sequencing, buffer management.
  • Benefits: Exceptional speed and scalability; modular upgrades for added lanes/levels; ideal for dense SKU profiles with fast-moving inventory.
  • Use Case Example: E-commerce fulfillment centers deploy shuttle systems to handle thousands of SKUs with rapid order consolidation.

4) Carousel ASRS (Horizontal & Vertical)
Carousels rotate shelves or bins to deliver items to the operator.

  • Best for: Small parts, batch picking, service parts environments.
  • Benefits: Space efficiency, rapid access to many SKUs, reduced walking and “search time,” safer ergonomics.
  • Use Case Example: Automotive service centers use vertical carousels to store thousands of parts in a compact footprint.

5) Robotic/AMR-Enabled Goods-to-Person
Modern ASRS architectures increasingly integrate AMRs or robotic arms for autonomous transport and pick/pack.

  • Best for: Flexible operations with changing SKU profiles; labor augmentation; scalable growth.
  • Benefits: Rapid deployment, lower disruption to existing layouts, easy scaling, improved safety.
  • Use Case Example: Retail distribution centers use AMRs to move goods from ASRS storage to packing stations, reducing manual touches.

Key Benefits of ASRS Systems

Implementing an ASRS system delivers transformative advantages:

  • Space Optimization: ASRS systems maximize vertical and horizontal space, often reducing facility footprint by 30–60%. This can defer costly building expansions, skyrocketing operating costs, and lower real estate costs.
  • Improved Accuracy: Automated retrieval minimizes human error, ensuring inventory accuracy and reducing costly mistakes.
  • Enhanced Productivity: Faster and more efficient picking and storage processes boost throughput, enabling companies to meet tight service level agreements and seasonal peaks.
  • Labor Savings: Reduce reliance on manual labor, lowering operational costs and mitigating workforce shortages.
  • Safety & Ergonomics: Goods-to-person workflows reduce strain, eliminate excessive walking, and minimize forklift traffic—creating a safer work environment.
  • Scalability: ASRS systems are modular, allowing businesses to add aisles, shuttles, or stations as demand grows.
  • Data Visibility: Integrated software provides real-time inventory tracking, enabling better forecasting and decision-making.

Muratec USA: A Legacy of Innovation

For decades, Muratec USA has advanced automation with ASRS systems that elevate performance, quality, and flexibility across global supply chains. Muratec’s heritage in precision engineering, controls, and software integration empowers customers to streamline complex operations, from manufacturing and kitting to distribution and service parts.

The Muratec Uni-SHUTTLE is the strategic answer to industry challenges, offering flexible load handling for various sizes and high-capacity transport. 

Muratec ASRS Solutions Include:

  • Uni-SHUTTLE HP: A high-performance shuttle system for ultra-fast case, tote and tray handling. Ideal for e-commerce fulfillment and sequencing buffers. Modular design ensures scalability.
  • Unit Load ASRS: Robust stacker cranes for palletized storage in high-bay warehouses. Perfect for finished goods, WIP, and cold storage.
  • Mini Load ASRS: Lightweight cranes for rapid tote retrieval in kitting, assembly, and spare parts operations.
  • FX Series: A flexible ASRS platform for mixed-load environments, combining advanced software with adaptable hardware.
  • Integrated Robotics & AGVs: Automtated guided vehicles and robotic picking arms create fully automated goods-to-person workflows.
  • Stage Scalability: Build modularity into the initial design to add aisles, shuttles, or stations as demand grows.

Why Muratec?

Choosing the right ASRS partner is just as important as selecting the right technology. Implementing an automated storage and retrieval system is a long-term investment that impacts every aspect of your operation from inventory control to order fulfillment speed. Muratec doesn’t just deliver equipment; we deliver confidence, collaboration, and proven expertise. Our approach ensures your ASRS solution is tailored to your unique requirements and supported for years to come.

  • Proven Global Impact: Trusted by leading manufacturers and distributors worldwide to improve supply chain efficiency.
  • End-to-End Partnership: From initial design and simulation to commissioning and lifecycle support, Muratec works as an extension of your team.
  • Reliability by Design: Robust mechanical systems and intelligent software ensure uptime and predictable performance.
  • Future-Proof Scalability: Modular systems and upgrade paths allow you to adapt to changing SKU profiles, order volumes, and fulfillment channels.

Ready to see the ROI of an ASRS system in your operation? When you partner with Muratec USA, you gain more than equipment—you gain a collaborative team dedicated to designing a custom solution for your unique challenges.

Our experts work side-by-side with your material handling team to:

  • Model throughput and storage density with tailored simulations
  • Identify quick wins for labor savings and accuracy
  • Build a scalable roadmap aligned to your growth and budget.

Contact Muratec USA today to start building an ASRS solution that transforms your warehouse into a high-performance, future-ready operation.