There’s increasing pressure on warehouse owners and operators to make more of the storage space available to them. This doesn’t just mean the floor space itself, but the vertical space, extending all the way up to the warehouse’s roof.
Vertical lift systems make this possible. And, as your automation and material handling experts, the BoxLogix team will explore how vertical lift modules help industry leaders.
A simple way to think of a vertical lift module is like an elevator, but for products, not people. It’s an enclosed automated storage and retrieval system (ASRS) in which products are stored in vertical stacks of trays. An internal ‘extractor’ mechanism can then find and retrieve any of those trays, when requested by the module’s operator and deliver the goods directly to the worker via a hatch.
VLMs help warehouse operators maximize storage density by making the most of the vertical space available to them; in other words, they allow managers to think upwards, not just outwards. They’re common solutions in warehouses that are shifting away from person-to-goods (P2G) models towards more automated and efficient goods-to-person (G2P) workflows.
P2G models often involve traditional shelving and conventional workflows. That means employees having to do much of the work, sometimes walking multiple miles daily across the warehouse floor. The end results of this often include inefficiency, higher likelihoods of fatigue and injury, and failure to make the most of the facility’s valuable floor space.
With a G2P module, automated storage systems take over large parts of the storage and retrieval processes. This saves workers time and energy. VLMs are particularly valuable pieces of automated technology, as they allow large amounts of inventory to be stored on a small amount of floor space, thanks to the power of vertical storage.
Vertical lift modules are used across a wide range of industries that need to maximize storage density, improve picking efficiency, and maintain tighter inventory control.
Manufacturing, ecommerce, aerospace, automotive, and pharmaceutical facilities all commonly use VLM technology to support faster retrieval times and more organized storage workflows. These systems are also frequently implemented in cold storage environments, MRO operations, and spare parts facilities where space optimization and inventory accuracy are especially important.
A vertical lift module uses automation technology to store, retrieve, and deliver inventory through a centralized goods-to-person workflow. Below is a step-by-step breakdown of how a VLM system operates:
Products are placed into trays. These trays come in various heights, widths, and weight capacities. Once they’re loaded up, they move into the module.
The system takes over. Height sensors check the dimensions of the trays as they enter the module. They’re then placed at just the right locations to maximize space optimization.
An operator requests a tray. The extractor receives the request, finds the tray’s location, and retrieves it. It’s delivered to a hatch at the module’s base.
In a traditional shelving environment, pickers may spend much of their shift walking aisle-to-aisle searching for SKUs, especially during peak fulfillment periods. With a VLM, operators remain at a centralized access point while the system automatically retrieves the required tray, reducing unnecessary travel time and helping teams maintain faster pick rates throughout the shift.
When the operator is finished with a tray, it goes back into the system to its designated location. A vertical lift module can also be customized over time to place the most in-demand inventory closer to the access point for even faster delivery.
Vertical lift modules rely on several integrated components working together to automate storage, retrieval, and inventory management workflows. While designs can vary between systems and manufacturers, most VLMs include the following core components:
These store the products/materials to be kept in the vertical lift module. They typically offer adjustable configurations and come in various forms to support various forms of inventory.
Responsible for storing and retrieving trays, helping to provide fast and accurate inventory management and G2P movement.
An ergonomic retrieval point where workers can comfortably access the items they need to fulfill orders, or store fresh stock away in VLM trays.
These components measure trays as they enter the module to help place them efficiently.
The brain of the system is responsible for tracking inventory locations so the tray always knows where to go. This can often integrate with other warehouse inventory control programs or WMS.
These help to prevent accidents and injuries. Examples include light curtains and controlled access points.
From improving picking productivity to reducing floor space usage, vertical lift modules can support several important warehouse optimization goals.
Here’s a closer look at some of the key benefits VLM systems offer:
One vertical lift module can store several tons of products/materials. It does this without taking up vast swathes of floor space. By organizing items vertically, not horizontally, operators can make much greater use of the room they have.
Compared to conventional P2G models, VLMs can dramatically increase picking speed and overall productivity by finding and delivering products to workers in a matter of seconds.
VLMs, together with WMS software, keep precise logs of their contents. They’re not prone to making mistakes or misplacing items, like human workers sometimes are. Their high accuracy can help operators avoid stock-outs and similar problems.
Operators have a safer and more comfortable experience working with VLMs as opposed to traditional shelving. They don’t have to walk, bend, climb, or reach as much because products are delivered directly to them.
A single operator can manage multiple vertical lift module systems. In addition, these systems ease the burden on the workforce by automating large parts of storage and retrieval. They’re also quite easy to work with, so there’s no need to worry about lengthy or complicated on-boarding.
VLMs secure inventory within an enclosed space, with controlled access for trained operators only. The enclosed nature of these systems also helps to keep items clean and less likely to be damaged or lost during storage or retrieval.
While traditional shelving systems are still common in many warehouses, they often require significantly more floor space and manual labor to manage inventory efficiently. Vertical lift modules offer a more automated, space-efficient alternative by delivering inventory directly to operators through a goods-to-person workflow.
When comparing VLMs to conventional shelving systems, keep in mind these elements:
Traditional shelving can only reach a certain height, as it has to be accessible for workers. VLMs can go significantly higher, while also taking up less floor space, maximizing storage density.
Traditional shelving is highly reliant on operators to do much of the hard work in terms of finding, picking, and transporting goods. In VLMs, internal extractors take over these tasks to reduce travel time.
Since traditional shelving is highly reliant on people, mistakes may happen as fatigued workers pick the wrong items. Automated VLMs are significantly less likely to make mistakes.
Traditional shelving can require workers to climb, bend, or reach in uncomfortable and possibly unsafe ways. VLMs reduce the amount of physical strain on workers, who can remain at their designated stations and wait for products to come to them.
Traditional shelving has much tighter scaling limits than VLMs, as it takes up greater amounts of floor space. VLMs are more easily aligned with growth and development plans since they use less space to store more goods.
Prospective buyers will typically want to consider the cost of a vertical lift module to help them decide if it’s a worthwhile investment. They should also think about how much it might help them save on labor costs, as well as the space it can help them recover.
Any facility with limited floor space can benefit from a VLM. Locations with high ceilings also stand to make the most of this technology, as that gives more room for vertical storage. Warehouses with diverse SKUs or tight labor constraints are also ideal candidates.
While vertical lift modules offer significant operational advantages, they are not without challenges. Like most warehouse automation investments, successful VLM implementation requires careful planning around system design, workflow integration, and long-term operational goals.
Some potential challenges facilities should consider include:
Choosing the right vertical lift module involves more than simply selecting a storage system that fits your facility. Warehouses should evaluate their inventory profiles, operational workflows, throughput requirements, and long-term growth plans to ensure the system aligns with both current needs and future scalability goals.
Here are some of the most important factors to consider when evaluating a VLM solution:
Look at the types and sizes of the products your facility tends to store. Also, bear in mind the weight of these items, as that will likely impact which type of VLM modules and trays you can use.
VLMs come in different heights, and some may not fit in your warehouse, depending on how high the ceilings are. You also need to ensure there is sufficient floor space for each module.
Consider the typical number of orders you have to fulfill in a given day, week, or month, and what sorts of retrieval speeds you want to achieve to maintain or optimize your operations.
Ideally, you’ll want to choose a VLM that can easily integrate with your existing warehouse tech stack, such as your WMS and enterprise resource planning (ERP) system.
Think ahead to how your operations might grow in the years to come in order to choose a system that can meet your needs not only now, but into the future.
It’s easy to make mistakes when investing in this type of technology for the first time. New buyers are recommended to work with trusted automation specialists, like BoxLogix. We can provide advice on everything from warehouse layout to system design.
More and more warehouses are investing in VLMs. It’s not difficult to see why. These automated systems can improve efficiency and space utilization. They can transform struggling facilities into well-oiled machines, with safer employees and speedier processes, all around.
However, in order to enjoy those benefits, you have to choose the right solution to suit your facility goals. That’s where BoxLogix comes in. Our experts can assist you in selecting the ideal VLM and other automation equipment.
Contact our team to discuss the right VLM solution for your facility.
A vertical lift module can help warehouses recover significant amounts of floor space by utilizing unused vertical cube space instead of expanding horizontally with traditional shelving. While the exact amount varies depending on ceiling height, inventory type, and facility layout, many warehouses use VLMs to dramatically increase storage density within a much smaller footprint.
Vertical lift modules are commonly used in manufacturing, ecommerce, aerospace, automotive, pharmaceutical, and cold storage environments. These industries often rely on VLM systems to improve inventory organization, increase picking efficiency, and support high-density storage for parts, components, tools, and other frequently accessed inventory.
The main difference between a vertical lift module and a carousel system is how inventory is stored and retrieved. VLMs use an extractor mechanism to retrieve trays from inside an enclosed vertical system, while carousel systems rotate shelves or bins to bring products to the operator. VLMs are often preferred for maximizing vertical storage density and supporting more flexible tray configurations.
For many warehouses, vertical lift modules can provide strong long-term value through improved storage efficiency, reduced operator travel time, and better inventory accuracy. Facilities with limited floor space, high SKU counts, or labor-intensive picking operations often see the greatest return on investment from VLM technology.