High-bay warehouse

In the logistics industry, high-bay warehouses are rack systems that are between 12 and 50 meters high and built in silo design. They are characterized by large storage volumes and the use of space up to ceiling height. Another characteristic feature is the automated use of the high-bay warehouse. This enables optimization of the material flow and warehouse management. Goods are stored and retrieved using automatically controlled computers. Warehouse staff or digitalized transport systems take over the incoming and outgoing goods at predetermined delivery points. This form of warehousing is primarily used by companies that store large quantities of products or require a high turnover rate.

Advantages of a high-bay warehouse

• Large capacity
• High space and room utilization
• Fast storage and retrieval
• Fully electronic control with a warehouse management system
• Storage of flat goods and long goods possible
• High efficiency with reduced personnel requirements

Structure and function of a high-bay warehouse

High-bay warehouses are characterized by high racking systems that are divided into several levels. They can be adapted in shape and size for individual purposes so that goods of different sizes and shapes can be accommodated. Depending on the loads they are intended to carry, heavy-duty shelving can be used for storage. Heavy-duty shelving is particularly suitable for large and heavy loads. They are used particularly frequently for pallet storage. Depending on what is to be stored, special sub-forms can also be used, such as cantilever racking, which usually carries long goods. High-bay warehouses are particularly suitable for small floor areas, as they can be built up to 50 meters high. For many companies with a lack of space, this can be a decisive factor in maximizing the available storage area.

Storage and retrieval in and out of a high-bay warehouse can take place in various ways. In warehouse logistics, two methods predominate: First in, First out (FIFO) and Last in, First out (LIFO). These are storage strategies in which the goods are removed either against the sequence or in the sequence in which they are stored. The manual or automated high-bay warehouses are designed so that forklift trucks, automated guided vehicles (AGVs) or roller conveyors can easily store or retrieve goods.

Automated high-bay warehouses are efficient

Automated systems also work with storage and retrieval machines that are able to load and unload shelves independently. For safety reasons, the storage areas are also cordoned off for staff. Instead, IT systems are used to control and coordinate the goods processes. Investing in an automated high-bay warehouse is very expensive. However, it is worthwhile as it reduces the workload on staff and optimizes the use of resources. There are also further advantages. The fast and precise handling of goods is efficient. This advantage is visible in several areas.

Space saving: High-bay warehouses enable vertical storage. This and the use of automated equipment allow the available space to be optimally utilized.

Safety: The use of modern machines supports safe work processes and reduces the risk of accidents or damage.

Error reduction: This is also reflected in the error rate, as automation ensures a high level of accuracy and therefore reduces errors during storage and retrieval.

Some examples of the largest high-bay warehouses worldwide

Consumer goods manufacturer Henkel invested around 36 million euros in its central warehouse in Düsseldorf in 2017. Capacity increased from 90,000 to around 200,000 pallets (Photo: Henkel)

For Tchibo, one of Germany's largest consumer goods and retail companies, BLG International Logistics built a high-bay warehouse in Bremen in 2002 for a total of more than 180,000 pallets. (Photo: BLG Logistics)

The organic food company Alnatura has been using the world's largest wooden high-bay warehouse with around 31,000 pallet spaces in Lorsch in southern Hesse since 2013. (Photo: Alnatura/Marc Doradzillo)

In 2016, voestalpine Krems put a fully automated deep-freeze warehouse for foodstuffs into operation in Shenzhen in southern China. According to the company, the "world's tallest freezer" offers space for almost 70,000 pallets. (Photo: Voestalpine Krems)