Operating in the heavily regulated pharmaceutical industry, the client faced several real-world warehousing challenges — and these pain points formed the starting point for the entire solution design:

•Rapid business growth outpacing existing capacity.The client's business was expanding quickly, and its existing warehouse could no longer keep up with growing      storage and throughput demands, requiring a large-scale system with sufficient capacity and room to grow.

•Strict regulatory requirements of the pharmaceutical industry.Pharmaceutical storage involves rigorous batch control, zone segregation, and traceability                  requirements. Traditional warehousing approaches carried compliance risks around inventory partitioning, error prevention, and cross-contamination control, so the        client needed a more rigorous approach to zoning and batch management.

•Rigid constraints on land and facility space.Maximizing the use of vertical space within the existing building — without adding to the facility footprint — was                central to the client's goal of controlling construction costs and shortening the expansion timeline.

•Bottlenecks in manual efficiency and accuracy.The traditional model of manual forklift operation fell short of the throughput, picking accuracy, and safety                    demanded by pharmaceutical production. The client wanted automation and flexibility to improve the speed and accuracy of storage and retrieval operations.

These challenges were closely interrelated: the client needed to store more, store accurately, store fast, and store safely — all while controlling land and construction costs. Meeting all of these demands simultaneously called for exceptional design and system-integration capability.

To address the client's specific challenges, Everunion's engineering team conducted a thorough assessment of the client's building conditions, workflows, and operational requirements, then designed and implemented a hybrid high-density storage system combining AS/RS cranes with 4-Way Shuttle Racking. This hybrid approach unites the space advantages of high-rise automation with the flexibility of horizontal movement, ensuring continuous, unobstructed inventory flow throughout the facility.

Step 1: Site Survey & Requirements Analysis

At project kick-off, the Everunion team carried out a comprehensive survey of the client's existing warehouse — building structure, available clear height, fire and safety codes, and pharmaceutical zoning requirements — to establish the key constraints the system would need to satisfy, including maximum usable height, floor loading capacity, and fire-zone layout. This provided an accurate foundation for the design that followed.

Step 2: System Design & Engineering Planning

Based on the survey findings, Everunion's design team developed an overall solution built around a 21-meter high-rise AS/RS crane system as the structural backbone, with 7.3-meter-deep 4-way shuttle racking as the core storage unit. The team also planned the location logic for all 11,630 pallet positions, ensuring that different product batches and categories could be clearly zoned and independently managed in line with the client's compliance requirements, while reserving expansion capacity for future business growth.

Step 3: Equipment Manufacturing & System Integration

Once the design was finalized, Everunion coordinated the precision manufacturing and factory testing of key equipment — cranes, shuttles, and racking structural components — under strict quality standards covering structural strength, operating precision, and safety performance. In parallel, the Warehouse Management System (WMS) was integrated and jointly commissioned with the equipment control system, achieving tight coordination between location management, task scheduling, and equipment operation ahead of on-site installation.

Step 4: On-Site Installation, Commissioning & Acceptance

Once equipment arrived on site, the Everunion team completed rack assembly, crane and shuttle installation, control-system commissioning, and both unloaded and loaded operational testing according to the project schedule. This confirmed that all key performance metrics — including retrieval accuracy, operating speed, and safety interlocks — met the design specifications before the system went live, and the team supported the client through final acceptance.

Through this systematic four-stage approach, Everunion translated the client's individual pain points into an executable, verifiable engineering solution — delivering a complete path from requirements to reality.

Key Results & Benefits

Since going live, the client has given the system high marks across performance, safety, and scalability, noting that it has not only relieved current pressures on storage capacity and compliance management, but also provided ample room and technical assurance for the company's continued growth.

The success of this project is another clear demonstration of Everunion's ability to deliver tailored, high-performance automated warehousing solutions for clients in heavily regulated industries such as pharmaceuticals. By deeply understanding the client's operational challenges, following a systematic engineering design process, and maintaining rigorous manufacturing and installation controls, Everunion helped the client achieve a comprehensive improvement in storage density, operational efficiency, and regulatory safety within a limited facility footprint — creating lasting, sustainable operational value.

Looking ahead, Everunion will continue to deepen its expertise in intelligent warehousing, drawing on core technologies such as AS/RS, 4-way shuttle systems, and intelligent logistics software to deliver one-stop, high-performance warehousing solutions — from design and manufacturing to installation and ongoing support — for clients across a growing range of industries.