What’s the difference between a vertical carousel (VC) and a vertical lift module (VLM)?

A vertical carousel functions like a Ferris wheel, storing small items on trays that rotate to deliver them. Introduced in the 1950s, it’s designed primarily for items of similar size and weight and is also known as a storage carousel or vertical rotating shelf system.

On the other hand, a vertical lift module is an automated storage and retrieval system that features a more advanced design, similar to a vending machine, allowing warehouse operators to safely retrieve inventory without rotating all its contents.

Right off the bat, VLMs offer clear advantages in most operations.

In this article, we’ll explore the mechanical and operational differences to help you decide whether investing in a vertical lift module is the right choice.

Vertical Carousel vs. Vertical Lift Module: Key Distinctions

Let’s explore the key differences between these two storage solutions and how they affect efficiency, space utilisation, and overall warehouse operations.

  • Balancing feature:Vertical carousels require careful weight distribution across trays to avoid overloading any single section, while vertical lift modules don’t and can retrieve items more swiftly.
  • Addressing space inefficiency:Vertical carousels have stationary shelves, which can lead to space inefficiency when large and small items share the same shelf. On the other hand, vertical lift modules come with adjustable tray heights. This effectively eliminates wasted space.
  • Maximising vertical storage:Warehouse employees can organise small and large SKUs into separate trays tailored to their dimensions when using vertical carousels, which are generally limited to heights of about 25 feet due to stability concerns. Alternately, vertical lift modules can extend beyond 50 feet, making them ideal for high-density storage.
  • Inventory accessibility:Vertical carousels move the entire shelving unit so warehouse operators can access inventory, reducing productivity and efficiency. Vertical lift modules, on the other hand, enable selective tray movement, enhancing operational speed.
  • Installation flexibility:Vertical carousels are built with a single solid end frame, making them bulky and challenging to install in certain locations. In contrast, vertical lift modules are composed of individual components, streamlining transport and assembly. Typically, installation takes just two days — half the time required for vertical carousels.

Key Advantages of a Vertical Lift Module (VLM)

Here’s how vertical lift modules can improve your storage and retrieval methods:

1.Increased Storage Capacity

Vertical lift modules optimise vertical space usage and maximise storage density by automatically adjusting tray heights to accommodate items of various shapes and sizes.

At Modula APAC, our unit’s trays are engineered to handle heavy loads, facilitating the secure storage of substantial items like automotive parts and bulk materials.

This capability is essential for pharmaceutical and automotive industries that need to access heavy materials quickly.

2.Space Efficiency

A survey found that 36% of respondents identified limited warehouse space as a significant challenge for warehouse operations.

This is where vertical lift modules come in handy, as they capitalise on high ceilings to make the most of the facility.

The result? A more organised warehouse with substantially increased free space and optimised storage capacity.

At Modula APAC, our VLM occupies just 150 square feet of your warehouse footprint, compared to the 9,050 square feet required for traditional storage methods. This dramatic reduction translates into more room for operations and storage expansion.

3.Faster Picking Retrieval and Efficiency

Slow service is a frequent source of customer dissatisfaction.

Vertical lift modules can expedite item retrieval, eliminating the need to wait for an entire set of trays to move.

Thanks to the extensive array of visual aids they offer, such as laser pointers that highlight the exact location of required items, VLMs enable quicker and more precise item retrieval for your operators.

Our Modula Lift modules deliver picking rates of over 300 lines per hour.

4.Improved Ergonomics

Operators often risk injury by reaching high and low to store and retrieve items, making warehouse environments accident-prone.

How can a vertical lift module minimise these risks?

Instead of operators traveling to retrieve goods, the items come directly to them. VLMs transport items to a convenient height, eliminating the need for bending, stretching, or climbing ladders.

This approach significantly reduces strain and injury risk for your warehouse employees.

5.Better Security

Worried about product security or potential theft?

Vertical lift modules are equipped with features such as badge and Electronic-Key-System (EKS) readers to guarantee that only authorised personnel can access specific products.

6.Scalability

As business demands increase, vertical lift modules can easily scale by adding more modules or reconfiguring the system to accommodate various types of goods.

This ensures VLMs can adapt seamlessly to fluctuating inventory levels or an expanding product range, providing a flexible storage solution that adapts to your business needs.

7.Energy Efficiency

Vertical lift modules are often engineered to be more energy-efficient than traditional manual storage systems.

Warehouse employees can program these modules to consume energy only when an operator activates the system to deliver a tray with items for picking. When not in use, the VLM remains electrically dormant.

Additionally, the VLM features an energy recuperation capability. A specially designed inverter harnesses the descending elevator’s kinetic energy and converts it into electricity that feeds back into the grid.

This results in up to a 40% reduction in energy consumption by the VLM.

How Do Vertical Lift Modules (VLMs) Operate?

Vertical lift modules leverage various automated systems to efficiently deliver inventory directly to warehouse operators:

  1. When a warehouse worker requires an item, they input the SKU information into a computer interface. The VLM control system, integrated with a warehouse management system(WMS), determines the quickest retrieval route.
  2. The inserter/extractor moves to the designated tray, secures it, and transports it to a delivery bay or access point where the worker can collect the item.
  3. Advanced VLMs are equipped with multiple access points, enabling different operators to retrieve items simultaneously, which significantly cuts down on wait times.
  4. After picking the SKU, the module restores the tray to its original location.

Find Cutting-Edge Vertical Lift Modules at Modula APAC

At Modula APAC, we provide automated vertical lift modules that utilise your facility’s available vertical space.

Our systems grant your warehouse staff convenient access to a vast inventory of security and safely stored products. Items are automatically brought to your warehouse employees at the touch of the intuitive Copilot controller or by scanning a barcode.

Final Notes on Vertical Carousels vs. Vertical Lift Modules

Though vertical carousels predate vertical lift modules, VLMs offer undeniable benefits.

Advantages include:

  • Saving warehouse space
  • Enhancing picking efficiency and speed
  • Creating a safe and efficient working environment
  • Boosting inventory security
  • Encouraging scalability
  • Supporting sustainability

Ready to make the switch to smart warehouse automation? Our team is here to guide you through the transition for a smooth integration tailored to your warehouse needs.