In high-volume warehouses and distribution centers, or facilities that are tight on space, efficient order picking is crucial for meeting customer demands and reducing operational costs. Rack-supported pick modules provide an innovative solution by integrating racking systems with conveyor belts, mezzanines, and shelving to streamline order fulfillment. With a system like this, you get the best of both worlds on the same footprint.
In this blog post, we’ll explore how rack-supported pick modules work, their benefits, potential drawbacks, and the types of operations that can benefit from them.
What Is a Rack-Supported Pick Module?
A rack-supported pick module is a multi-level storage and retrieval system designed to enhance order fulfillment efficiency. Unlike traditional racking, these systems can incorporate storage, multiple picking zones, conveyors, carton flow racks and more to create a high-density, high-speed picking environment.
Pick modules are often custom-designed to fit warehouse layouts and workflow needs, allowing for seamless product movement from storage to shipping.
How Rack-Supported Pick Modules Work
Rack-supported pick modules function by combining storage, picking, and transportation systems into a cohesive operation with a condensed footprint. A typical pick module setup can include:
Multi-Level Racking – Stores products in multiple zones, improving space utilization.
Carton Flow – Uses gravity-fed lanes to keep items within easy reach.
Conveyor Systems – Moves picked items efficiently through the facility, reducing manual transport.
Automated or Manual Picking Stations – Designed for both manual picking and automated systems to retrieve orders quickly, like pick to light or others.
These elements work together to minimize picker travel time, improve accuracy, and increase order throughput.
Benefits of Rack-Supported Pick Modules
Increases Order Picking Speed: Pick modules reduce the distance workers need to travel, speeding up fulfillment operations.
Maximizes Warehouse Space: Utilizing multi-level storage and dynamic flow racks optimizes every square foot of available space. This is a great system to use when warehouse space is limited.
Reduces Labor Costs: By streamlining order fulfillment and integrating automation, warehouses can reduce labor dependency.
Improves Order Accuracy: Well-organized picking & shipping operations reduce errors and mis-picks.
Enhances Scalability: Pick modules can be expanded or reconfigured as demand increases and product changes, making them ideal for growing operations.
Supports Multiple Order Types: These systems can handle both small parcel and palletized orders, accommodating various fulfillment needs.
Potential Drawbacks of Rack-Supported Pick Modules
Complex System Integration – Integrating pick modules with existing warehouse management systems (WMS) and conveyors may require specialized expertise.
Limited Flexibility – While scalable, major layout changes can be costly.
Despite these challenges, the long-term efficiency gains and cost savings often outweigh the initial investment.
Best Applications for Rack-Supported Pick Modules
Rack-supported pick modules are ideal for industries and operations that handle high-order volumes and fast-moving inventory, including:
E-Commerce & Retail Distribution – Improves order accuracy and speeds up online order fulfillment.
Grocery & Food Distribution – Handles high-turnover products efficiently.
Pharmaceutical & Healthcare Logistics – Ensures precise, rapid order picking for medical supplies.
Automotive Parts Warehousing – Manages large SKU counts in a compact space.
Third-Party Logistics (3PL) Providers – Optimizes fulfillment processes for multiple clients with varying order profiles.
Choosing the Right Pick Module for Your Warehouse
When selecting a rack-supported pick module, consider the following factors:
Order Volume & Picking Speed Requirements – Ensure the system can handle current and projected order demand.
Storage & SKU Density – Choose the right combination of shelving, flow racks, and conveyors to optimize storage.
Automation Integration – Determine whether conveyors, chutes or automated order picking can further enhance efficiency.
Warehouse Layout & Available Space – Design the pick module to fit seamlessly within existing operations.
Budget & ROI Expectations – Assess the investment costs versus long-term labor and efficiency savings.
Conclusion: Unlock Higher Efficiency with Rack-Supported Pick Modules
For businesses looking to improve order fulfillment efficiency, rack-supported pick modules provide a strategic solution by reducing picking time, maximizing space, and increasing order accuracy. While they require an upfront investment, their long-term scalability and efficiency gains make them an excellent choice for high-volume distribution centers.
Interested in optimizing your warehouse with a pick module system? Contact us today to explore how custom solutions can help your business scale effectively!
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