A Vertical Lift Module (VLM) is an automated storage and retrieval system designed to optimize vertical space within a facility. Often used in warehouses, manufacturing plants, and distribution centers, VLMs store items on trays or shelves inside a tall vertical cabinet. When an item is requested, the system automatically retrieves the tray and delivers it to an access window at an ergonomic height.
In today’s logistics and manufacturing environments—where efficiency, space, and accuracy are paramount—VLM systems offer a modern solution for inventory management, order picking, and storage automation.
VLMs make use of overhead space that is often underutilized. They can extend up to the ceiling, freeing up valuable floor space for other operations.
The automated retrieval process reduces human error in picking and enhances productivity by delivering items directly to the operator.
Operators receive materials at a comfortable height, reducing strain and improving workplace safety.
Integrated software allows for precise tracking of inventory, minimizing stockouts and overstocking.
Restricted access can be configured, and the system can log each access or transaction, increasing inventory control and reducing theft.
High Initial Cost: The upfront investment for machinery, installation, and software can be significant.
Maintenance Requirements: Regular maintenance is needed to ensure uninterrupted operation.
Not Suitable for All Items: Oversized, irregular, or heavy items may not be compatible with VLM trays.
Learning Curve: Staff must be trained to use the system and accompanying software.
Power Dependency: VLMs rely on electricity, and downtime can disrupt operations without a backup plan.
Ideal for small to mid-sized operations, these are installed in isolated spaces and operate independently.
These systems are connected to warehouse management software (WMS) and other automation tools for synchronized operations.
These feature two tray access openings, allowing one tray to be retrieved while another is being loaded or unloaded, thus reducing wait time.
Designed for sensitive items such as pharmaceuticals or electronics, they maintain specific temperature and humidity levels.
VLM systems are increasingly equipped with AI to optimize tray locations and predict inventory demand.
Robotic arms and conveyors are being integrated to automate end-to-end storage and retrieval processes.
Modern VLMs now support IoT integration, allowing managers to track inventory levels, conditions, and performance remotely.
Manufacturers are developing VLMs with energy-saving components like regenerative drives and low-power standby modes.
Systems are now designed to be easily reconfigured or expanded as the business grows.
| Feature | Importance |
|---|---|
| System Height & Tray Capacity | Ensure it fits your building dimensions and storage needs |
| Speed of Retrieval | Measured in picks per hour; affects operational efficiency |
| Software Integration | Compatibility with your ERP or WMS |
| Security Options | User authentication, access logs, and item-level tracking |
| Energy Consumption | Look for energy-efficient components |
| Load Capacity Per Tray | Must suit the weight and size of your stored items |
| Ease of Maintenance | Simple parts replacement, diagnostics, and vendor support |
| Company | Website | Notable Features |
|---|---|---|
| Kardex Remstar | kardex.com | Modular, scalable systems with integrated software |
| Modula | modula.eu | Dual-bay access, custom tray configurations |
| Hänel | haenel.de | Eco-friendly lifts, smart automation, and touchscreen panels |
| SSI Schäfer | ssi-schaefer.com | Advanced logistics integration with AI capabilities |
| System Logistics | systemlogistics.com | Custom VLMs for food and pharma sectors |
Comparison factors to keep in mind include regional support, warranty, software flexibility, and post-installation service quality.
Here’s a checklist to guide your decision-making process:
Are items standard-sized or irregular?
Are they high-value or fragile?
How fast do you need to retrieve items?
How many orders or picks per day?
What is the available ceiling height?
Are there floor weight limitations?
Will the VLM work with your existing WMS or ERP?
Do you require real-time data access?
Consider both the upfront and ongoing costs.
Ask vendors about hidden expenses like installation or training.
Always ask for a live or virtual demo before committing.
Observe the user interface, speed, and tray movement.
Train Employees Properly: Ensure users understand both hardware and software aspects of the system.
Regular Inspection: Schedule routine maintenance for belts, motors, and sensors.
Keep Software Updated: Use the latest updates to avoid bugs and improve functionality.
Organize Trays Logically: Group frequently accessed items in easier-to-reach zones.
Backup Power Supply: Use a UPS to prevent downtime during power outages.
Log System Usage: Monitor who is accessing the system and when, for better security and analytics.
Q1. How much space can a VLM save compared to traditional shelving?
VLM systems can save up to 80% of floor space by utilizing vertical height effectively.
Q2. Can VLM systems store items of different sizes?
Yes. Most modern systems have adjustable trays or dynamic height sensing to accommodate varying item sizes.
Q3. Are VLMs suitable for cold or hazardous environments?
Climate-controlled VLMs are available for temperature-sensitive or sterile items, though they cost more.
Q4. What is the average cost of a VLM system?
Pricing varies based on height, features, and vendor. A basic system can start at around $50,000 and go up to $150,000 or more for advanced setups.
Q5. Can small businesses benefit from VLMs?
Yes, especially in industries where space is a premium or inventory control is crucial. However, ROI should be carefully evaluated.
Q6. Is it possible to move a VLM after installation?
While possible, it requires disassembly and professional help. It is best planned as a semi-permanent installation.
Q7. What happens if the system malfunctions?
Most systems offer manual override features, and top vendors provide quick-response maintenance contracts.
Vertical Lift Module systems represent a significant advancement in automated storage technology. By improving space utilization, operational efficiency, and inventory accuracy, VLMs are increasingly seen as vital tools in modern logistics and manufacturing environments.
Choosing the right VLM involves balancing your current and future needs, understanding system capabilities, and investing in proper training and maintenance. While the initial investment may seem high, the long-term benefits—such as space savings, reduced labor costs, and improved order accuracy—can provide a compelling return.