The Ultimate Guide to Vertical Carousels

Which manufacturers produce Vertical Carousels?

Vertical Carousels are manufactured by both large and small companies around the world. The best-known global manufacturers are Kardex Remstar and Hänel, both based in Germany (although Kardex has its headquarters in Switzerland). Kardex has long maintained a strong and stable presence in Sweden, while Hänel operates in the country through distributors.

In addition to the manufacturers mentioned above, Constructor has historically been a major player in the Vertical Carousel market. Since 2023, Constructor has ceased manufacturing Vertical Carousels and is instead focusing on its Vertical Lift Modules. Expertise in servicing and spare parts for Constructor’s Vertical Carousels is still available.
In the Swedish market, it is primarily the above-mentioned companies that set the tone, but globally there are also machines from manufacturers such as:

• Jungheinrich
• Daifuku
• Linnex
• Vidir
• Alba
• et al.

How is a Vertical Carousel constructed?

Before we delve into the advantages and specific applications of Vertical Carousels and warehouse carousels, we will first describe the basic structure of the machine itself. The design is fundamentally relatively simple, a factor that contributes to the robustness and reliability of this type of machine. In simple terms, a machine consists of the following components:

• Gables
• Base shelves (Carriers)
• Cover plates
• Machine opening
• PLC/Control Panel
• Engine

The machine's storage capacity

There are more factors than just the machine’s end panels that determine a Vertical Carousel’s storage capacity—in particular, the storage shelves themselves—but the end panels are not unimportant.

In addition to being available in specific heights, the end panels also come in different depths. The depth of the end panels determines how deep the storage shelves can be mounted on the frame—and thus, ultimately, the storage capacity in terms of both floor space (m²) and volume (m³).

The depth of the end walls is usually somewhere between 1,250 mm (the narrowest version of the Vertical Carousel) and 1,750 mm (the deepest version).

Another important factor affecting the machine’s storage capacity is the thickness of the end panels. As a user, you don’t normally need to think about the thickness of the end panels, but to understand the machine’s design, this is determined based on the weight of the cargo the machine needs to handle and the machine’s height. A tall machine designed to handle heavy loads naturally requires slightly thicker steel in its base structure.

Storage shelves (carriers)

The storage shelves in a Vertical Carousel are often referred to in the industry as carriers. The configuration of carriers in a Vertical Carousel is a key factor in assessing the machine’s storage capacity in terms of area, volume, and weight. A carrier’s capacity is based on five key characteristics:

• The width of the carrier
• The depth of the carrier
• Aircraft height
• Number of intermediate shelves
• Maximum load capacity

The width of the carrier

When selecting a Vertical Carousel, the machine width—in addition to the machine height—is perhaps the most important factor to consider. The machine width determines the width of the machine’s shelves and is therefore a crucial factor in maximizing storage capacity.

Carriers for a Vertical Carousel are often available in standard sizes, and unless you place a custom order, the approximate dimensions listed below are what various manufacturers typically offer.

• 2,250 mm
• 2,450 mm
• 2,650 mm
• 2,850 mm
• 3,050 mm
• 3,450 mm
• 3,650 mm
• 4,000 mm

The depth of the carrier

The depth of the carrier is, of course, the second of the dimensions that determine the storage capacity of the Vertical Carousel in terms of storage area (m², carrier width × carrier depth). The depth of a carrier is typically available in three different sizes, with the following approximate dimensions:

• 400 mm (370 mm – 420 mm depending on the Manufacturer)
• 500 mm (470 mm – 520 mm depending on the Manufacturer)
• 600 mm (620 mm – 6,240 mm depending on the Manufacturer)

The depths are often designed to work well with standard sizes found in various types of storage bins.

Aircraft height

The height of a carrier is often referred to in the industry as “pitch.” Pitch is a very important factor when selecting a Vertical Carousel system, as it determines the maximum height of the goods that can be stored in the machine. A carrier in a Vertical Carousel has fixed dimensions, and all the base shelves in the system move closely above and below one another.

Unlike a Vertical Lift Module that can automatically accommodate varying cargo heights, a Vertical Carousel has a maximum height limit determined by the carrier pitch. Common carrier heights include, for example:

• 250 mm
• 300 mm
• 350 mm
• 400 mm
• 450 mm
• 500 mm

When discussing carrier pitch, it is important to verify whether the dimension specified by the supplier or Manufacturer refers to the outer dimension of the base shelf or whether it actually indicates the maximum stackable height.

The pitch of a carrier determines how many base shelves can fit in the Vertical Carousel, as well as how many intermediate shelves each base shelf can hold. A Vertical Carousel that is 8 meters high and has shelves with a pitch of 250 mm can naturally hold more shelves than if each base shelf were 450 mm.

Number of intermediate shelves

Another key component of a Vertical Carousel is what is known as intermediate shelves. Intermediate shelves are simply additional shelves that can be inserted into each carrier or base shelf—an effective way to create more storage space and an opportunity to increase the number of storage locations in the Vertical Carousel.

A common configuration, for example, is a carrier with a pitch (height) of 350 mm that can accommodate 2 additional shelves; this results in a carrier with 3 storage shelves, each of which can hold a storage bin or item with a maximum height of approx. 100+ mm.

Calculation of storage capacity

Taking the above components into account (carrier width, carrier depth, carrier height/pitch, number of intermediate shelves), you can calculate the capacity of a Vertical Carousel in terms of both floor area (m²) and volume (m³). The table below provides some examples of common models. If you need help with similar calculations, please feel free to contact us!

Maximum load capacity

A carrier’s maximum load capacity is often determined by the motor power of the Vertical Carousel; however, the design itself and the number of intermediate shelves are also significant factors. Since intermediate shelves have a certain weight of their own, it is generally true that the more intermediate shelves a carrier has, the less cargo weight it can carry.

Common maximum load capacities for a carrier are often, for example, 300 kg, 400 kg, or 500 kg. As a general rule, a carrier with a maximum load capacity exceeding 300 kg means that most businesses don’t need to worry too much about overloading. However, if you know you’ll be transporting relatively heavy cargo—such as various steel parts, tools, etc.—you should still be careful.

Below is an example illustrating the maximum weight capacity of a Kardex Vertical Carousel. Here you can see, for example, that there are also different types of intermediate shelves:

• Self-supporting shelves; these are slightly sturdier and heavier but do not require support brackets to stay upright.
• Simpler metal shelves; they are lighter, which allows for heavier loads, but require support plates to prevent them from bending.

Cover plates

Once the gables of a paternoste structure have been erected and the carriers installed, the structure is covered with metal sheets, known as cover plates. The primary function of the cover plates is to enclose the machine, making it safe and aesthetically pleasing, but they also serve to reinforce the structure to some extent.

One thing to keep in mind regarding cover plates when purchasing used Vertical Carousels is to check that none

Plates are missing. When machines were previously arranged in pairs or groups and are then moved, plates may sometimes be missing if you want to place the Vertical Carousel on its own. Plates can be replaced, but this can be relatively expensive if they have to be ordered from the Manufacturer.

Machine opening

The machine opening—or simply “the opening”—of a Vertical Carousel plays a central role, as it is where goods are both loaded into and unloaded from the machine. When it comes to the machine opening, there are a few important aspects to consider:

Security

The most important safety system in the Vertical Carousel is located at the opening—the light curtain. The light curtain consists of laser sensors that run horizontally along the entire length of the opening and ensure that neither goods, arms, hands, nor fingers can enter the shelves while the Vertical Carousel is rotating.

If you hold out your finger, or if an object or a box falls out and suddenly breaks the light curtain, the Vertical Carousel will stop immediately.

Height of the opening

A common argument for storing goods in a Vertical Storage System such as a Vertical Carousel is that it allows the operator or picker to work ergonomically—this requires that the machine’s opening be at a suitable height.

By default, the opening on a Vertical Carousel is located approx. 1 meter up.

When ordering a custom-built Vertical Carousel, you can adjust the height of the opening. Adjusting the machine’s opening is usually necessary, for example, if the Vertical Carousel has been installed in a recessed area of the floor and you therefore want the opening to be slightly higher.
It could also be, for example, because there are products that need to be handled using a specific forklift or material cart

Workbench

The work tables in the opening are the tables that extend horizontally in line with the opening, providing support and a work surface when handling products being loaded into or unloaded from the machine.

The worktable is usually 300 mm deep and made of some type of sheet metal. When measuring a machine’s depth, the depth of the worktable is often excluded, so keep this in mind when looking at a panel saw. A machine with a depth of, for example, 1,600 mm therefore often has a total depth of 1,900 mm, including the worktable.

The workbench is very practical for both storage and picking, as you can pull it out and let any storage bins that the Vertical Carousel is filled with rest on the workbench while handling the goods.

It is possible to choose different worktable surfaces if, for any reason, you have products that may be sensitive to certain materials. For example, you can cover the worktable with a plastic or plexiglass surface if the products must not come into contact with other metals. Similarly, the Vertical Carousel can be installed without a worktable.

PLC/control panel

The PLC, or control panel as it is also known, is the built-in “computer” in the machine that allows you to control it. Manual control of a Vertical Carousel usually involves entering the tray level you want to be presented in the machine’s opening.

The control panel also provides access to various settings and information about the machine, though most of this is not relevant to a typical operator.
The control panel is usually located above the machine's opening, to the side of it, or in a separate enclosure, such as a control cabinet or similar.

In some cases, the PLC/control panel may offer a bit more system support, such as the ability to track item numbers and inventory levels. We rarely recommend using this functionality; it works better to place a standard PC next to the machine and continue managing inventory levels, etc., in your WMS system. If you have more specific requirements regarding the control and integration of Vertical Storage Systems and Vertical Carousels, you can read more about it here.

Engine

The Vertical Carousel Elevator The motor can be a determining factor in how heavy a load can be loaded into the machine. In addition to the fact that a larger motor allows for the handling of heavier loads, the motor model also often determines the robustness of the machine’s other components, such as the thickness of the end plates and the maximum load capacity of the carriers (as described in the previous section).

For Kardex, for example, the motor model and capacity are specified in the model designation below

• Kardex Megamat RS 180
• Kardex Megamat RS 350
• Kardex Megamat RS 650

To put it simply, the models above can handle 180 kg, 350 kg, and 650 kg per carrier/base shelf, respectively. However, as mentioned, the maximum capacity of a Vertical Carousel is determined by more factors than just the motor.

Machine width, number of intermediate shelves, machine height, and motor power can all interact; examples of how a machine’s capacity is illustrated on the Vertical Carousel itself can be seen below. Manufacturers usually provide clear tables on their websites as well.

Optional accessories for Vertical Carousels

In addition to the standard components of a Vertical Carousel system, there are a number of optional features available for the machines—features that are often already included on used machines or can be customized when ordering a new system. Below are some common solutions and options:

Machine door

Purchasing a machine door for a storage carousel is a very common solution. The machine door allows the opening on the unit to be closed, either automatically or manually. Using a door helps prevent dirt and dust from entering the machine when it is not in use.

A lock on the Vertical Storage System can also be useful for securing valuable items, thereby reducing loss and theft.

LED strip

A popular option for improving both the speed and safety of picking from a Vertical Carousel is what is known as an “LED strip.” The LED strip is a light strip that is milled into the machine’s worktable at the opening and can display information via LED lights and text, simplifying and speeding up the operator’s work.

The most common use is for the list to clearly indicate where on the shelf the items are to be picked. It is also common for the list to include, in addition to the picking location, details such as the item description and the quantity to be picked—thereby reducing the risk of picking errors.

ESD design

If you work with products that are sensitive to static electricity, you can order ESD-protected Vertical Carousels. Components in the machine can be replaced with ESD-protected alternatives, and, most importantly, you can obtain ESD-protected drawers and interior fittings for the Vertical Carousel.

Double openings

Another optional feature for Vertical Carousels is dual openings, meaning two lift car openings at different height levels. This can be a very practical option if you want to utilize a Vertical Carousel on, for example, two different floors. A common application is one opening at ground level and one at mezzanine level.

How do you choose the right Vertical Carousel?

If you’ve decided to invest in one or more Vertical Carousels, there are, of course, plenty of reasons to choose from a wide variety of configurations, models, and types; however, below are our top recommendations.

Machine dimensions

The most common and obvious factor to consider before purchasing a Vertical Carousel is the layout of your property.

To get the most out of a Vertical Storage System, you should always aim to maximize the available height. As a rule of thumb, you can actually purchase a machine that is as close as 50 mm to your maximum ceiling height. Keep in mind that you should measure from the lowest point of the ceiling, for example, if you have a sloped ceiling.

After height, width is the next major dimension to consider. The difference between a narrow and a wide Vertical Carousel can be as much as 1.75 meters—the storage capacity of a machine with 4,000 mm wide carriers is 70% higher compared to a machine with 2,250 mm wide carriers. If you have the space, we recommend choosing the widest Vertical Carousel possible.

When it comes to the depth of a Vertical Carousel, the difference in overall dimensions between a deep and a shallow machine is at most 500 mm. The carriers/shelves come in depths of 400 mm, 500 mm, and 600 mm—so the maximum difference between a shallow and a deep machine is 50%. On the used market, Vertical Carousels with 400 mm depth are very rare; therefore, if you find the right machine in terms of height and width, don’t get too hung up on this measurement.

Capacity

Storage space

When selecting a Vertical Carousel, matching your required capacity with the machine’s capacity is perhaps the most important factor to consider.

The most common setup in a fully manual warehouse involves shelving units filled with storage bins. These shelving units are compact, but typically do not exceed a height of 2 to 2.4 meters. A Vertical Carousel matches the compactness of shelving units, but makes use of the ceiling height, thereby saving a significant amount of floor space.

To estimate your current usage, you can calculate it as follows:

• Number of rows of shelving (e.g., 10)
• Number of sections with shelving units per row (e.g., 4)
• Number of shelves per section (e.g., 5)
• Dimensions per shelf (e.g., 600 mm depth x 1,000 mm width)

The shelving unit shown above has a storage capacity calculated as follows:
10 rows × 4 sections × 5 shelves × 0.6 m² (600 mm × 1,000 mm) = 120 m²

This capacity is likely distributed over an area of approx. 80 m², as shown in the illustration below.

For comparison, refer to the table above. The calculation is the same, but based on the conditions in a Vertical Carousel:

• Number of carriers (e.g., 31)
• Number of additional shelves (e.g., 62)
• Dimensions per carrier (e.g., 528 mm x 3,250 mm)

The Vertical Carousel described above has a storage capacity calculated as follows:

93 shelves (carriers + intermediate shelves) × 1.716 m² (528 mm × 3,250 mm) = 159.6 m²

These 160 m² can be stored in just 6 m² of floor space; the machine measures 1.57 m x 3.88 m.

Storage capacity

In most cases, calculating the storage area is sufficient to get a good idea of the storage requirements for a Vertical Carousel. Since Vertical Carousels are designed for relatively small products, volume is rarely a major issue; the main challenge is creating a very large number of storage locations (sometimes thousands) within a small space.

If you’d like to calculate the storage volume in more detail, you use the exact same calculation as above for storage area, with the addition that you need to include the height of each shelf in the equation.

One possible scenario could look like the one below.

Shelving unit with 500 mm spacing between shelves (2.5-meter-high shelving unit):
10 rows x 4 sections x 5 shelves x 0.6 m² (600 mm x 1,000 mm) x 0.5 m = 60 m³

Vertical Carousel with a 350 mm pitch on the carrier:
93 shelves (carriers + intermediate shelves) × 1.716 m² (528 mm × 3,250 mm) × 0.35 m = 55.85 m³.

As you can see in the example above, Vertical Carousels offer lower capacity in cubic meters than shelving units; the reason for this is that there is usually a lot of empty space between the shelves in a shelving unit, whereas a Vertical Carousel is often packed tightly.

Maximum dimensions of the cargo

When evaluating which Vertical Carousel to purchase, it’s important to consider the maximum dimensions of your goods; the most important factor to evaluate is the height of the goods you plan to store. Vertical Carousels are excellent Vertical Storage Systems for storing small items compactly in a small space—but if you have slightly bulkier items, they may not be suitable for your needs.

If you have products that have heights of 300 mm, 400 mm, or perhaps even 500 mm, be extra careful to check the “pitch” of the carrier or base shelf. If the machine has a pitch of 350 mm, it is simply not possible to store a product that is 400 mm high (unless it can be laid flat or similar, of course).

The same applies to the length and depth of your goods: be sure to carefully check the dimensions of the carrier or base shelf. While it’s ultimately unlikely that all goods and all types of dimensions will fit in a single machine, if you can fit the vast majority of your goods into the machine, the investment will usually prove worthwhile anyway.

Weight

It is also important to consider the maximum load capacity of a Vertical Carousel before purchasing one. Generally, Vertical Carousels can handle a maximum load of 300 kg, 400 kg, or 500+ kg per carrier or base shelf—a capacity that meets the needs of the vast majority of businesses.

If you know that your goods are relatively heavy, the easiest way to determine your storage needs is to mark out the area of a carrier or shelf on the floor or on a table. Then place the goods you intend to store on the marked area and weigh them—did the total weight exceed or fall short of the carrier’s maximum capacity?

Number of machines

Storage capacity

If storage capacity is your primary concern, your evaluation should be based almost entirely on the calculations shown in the section above—specifically, those regarding storage area and storage volume. Vertical Carousels cannot be built to be arbitrarily large, and the ceiling height of a company’s facility is often the main limiting factor.

Our example a little earlier was a 6.7-meter-high Vertical Carousel with a total storage capacity of 160 m² in a warehouse with a corresponding ceiling height of approx. 6.7 m, but where the storage requirement is 320 m²—so you can simply assume that you’ll need two machines.

Picking efficiency

When it comes to picking efficiency, determining the number of machines needed immediately becomes more complicated, but there are some guidelines.

First and foremost, it’s safe to say that if you’re aiming to improve picking efficiency, you should always purchase two or more Vertical Carousels. A single Vertical Carousel primarily offers significant space savings, but when using two or more, combined with a good WMS or business system, you can achieve impressive figures in terms of picks per hour.

A well-designed picking strategy using two or more Vertical Carousels can enable a warehouse worker to pick 100–250 picking lines per hour, compared to manual picking, which typically averages 50–70 picking lines per hour.

A picking station designed for maximum efficiency typically includes 3–4 Vertical Carousels per picker—with this setup, the picker never stands idle waiting for the machines, but maintains a high picking pace at all times.

Selection of a manufacturer of Vertical Carousels

The companies that manufacture Vertical Carousels are all reputable firms with high-quality products, but the choice of supplier or Manufacturer is, after all, of the utmost importance.

Our top tip when evaluating a manufacturer is to focus on the complexity of your needs.

Are you planning to buy a single Vertical Carousel that will see limited use, mainly to save space? In that case, the Manufacturer will play a fairly minor role once the machine is installed. The products are extremely reliable, and you’ll rarely need support.

Are you planning to purchase six Vertical Carousels, with the majority of your inventory to be stored in them, and do you need assistance with a major IT integration? If so, it is important to thoroughly evaluate the Manufacturer’s capabilities.

Here are a few suggestions for things to look into:

• What is the Manufacturer's delivery time for a machine?
• What is the Manufacturer's lead time for replacement parts?
• How many service technicians does the supplier have locally?
• Is local phone support available?
• Does the manufacturer have experience with solutions similar to the ones we are looking for?
• Are there any references we can contact to hear about their experiences?

Summary

Investing hundreds of thousands (or millions) of kronor in a Vertical Carousel may seem like a big risk, but in our experience, it is extremely rare for us to see customers and companies that do not derive significant benefits from their Vertical Carousel systems.

This guide provides a fairly comprehensive overview of the key information and decisions to consider before purchasing a Vertical Carousel—but of course, there are special cases and issues specific to your situation that you’ll need to explore further.

Whether you are interested in used products or would like assistance in evaluating the purchase of a new Vertical Carousel, we are happy to assist you.

Feel free to contact us via the form, email, or phone!