Smart AS/RS Storage Solution for Automotive Component Manufacturer Handling Oversized
Project Overview
Location: Nantong
Industry: Precision Machining & Automotive Components
Solution: Customized Beam-Type AS/RS Racking System
A leading automotive component manufacturer in Nantong, China specializes in precision machining and metal component production for global automotive supply chains.
With continuous production expansion, the company's existing storage system could no longer meet its growing operational requirements. The warehouse needed to handle multiple categories of materials, including long bar materials, metal coils, semi-finished components, and finished products — all with different sizes, weights, and storage requirements.
To improve warehouse efficiency, maximize storage capacity, and ensure reliable material supply for production, the client required a customized automated storage solution capable of handling oversized and heavy industrial components.
Project Challenges
1. Oversized and Irregular Materials Required Customized Storage Design
Unlike standard palletized goods, the client's materials included:
Long bar materials up to 3,500×500×650mm
Finished components up to 1,000×1,200×1,300mm
Semi-finished products up to 1,500×1,500×800mm
Traditional pallet racking systems could not provide stable support or efficient space utilisation for these irregular cargo dimensions.
The warehouse required a storage system specifically engineered around the customer's product characteristics.
2. Limited Warehouse Space with Increasing Storage Demand
As production volume increased, available warehouse space became a critical challenge.
Expanding the building footprint would require significant investment and disrupt existing operations.
The client needed a solution that could:
Increase storage density
Fully utilise vertical warehouse space
Store more materials within the existing facility
3. Heavy Materials Required High Structural Reliability
The stored products included heavy metal materials and precision components.
Each storage position needed to safely support loads up to:
1,500kg per pallet
while maintaining long-term stability under frequent storage and retrieval operations.
4. Production Efficiency Required Faster Material Access
For manufacturing enterprises, warehouse efficiency directly impacts production continuity.
The client required an automated system that could:
Reduce manual handling
Improve material locating efficiency
Ensure accurate inventory management
Support continuous production operations
Customized AS/RS Solution
Everunion Storage designed and delivered a customized beam-type AS/RS racking system specifically developed for the client's oversized metal components and automotive manufacturing requirements.
High-Density Vertical Storage Design
The system adopted an ultra-narrow upright frame design with only 350mm depth, allowing more storage positions within the same warehouse footprint.
With a system height of 15,975mm, the solution maximised vertical space utilisation and significantly increased storage capacity without requiring warehouse expansion.
Engineered for Oversized and Heavy Industrial Materials
To accommodate different cargo dimensions, Everunion customized:
Beam lengths: 3,260mm & 3,660mm
Rack structure based on actual cargo specifications
Heavy-duty storage positions supporting 1,500kg per pallet
This ensured stable storage for long bar materials, coils, and large semi-finished components.
Seamless Automation Integration
The racking structure was precisely engineered to integrate with AS/RS automation equipment.
Through accurate structural design and installation control, the system achieved reliable automated storage and retrieval operations, helping improve warehouse efficiency and reduce dependence on manual handling.
Complete Project Support
Everunion provided full-cycle service including:
Storage planning consultation
Customized engineering design
Manufacturing
Transportation
Installation
Final commissioning
The complete project management approach ensured smooth implementation with minimal impact on the customer's production activities.
Project Results
Maximized Warehouse Capacity Without Expansion
By utilizing high-rise AS/RS technology, the client significantly improved storage density within the existing warehouse area, avoiding additional construction investment.
Safe Storage for Complex Industrial Materials
The customized rack structure successfully solved the challenge of storing oversized and irregular metal components, eliminating inefficient temporary storage methods.
Improved Warehouse Operation Efficiency
Automated storage and retrieval reduced manual material handling requirements, improved inventory accuracy, and enabled faster material availability for production.
Long-Term Scalability for Future Growth
The modular AS/RS solution provides flexibility for future production expansion, supporting the client's continued business development.
Why Everunion
With more than 20 years of experience in industrial storage solutions, Everunion Storage specializes in designing customized warehouse systems for manufacturing industries.
From automated storage systems to heavy-duty industrial racking, we help manufacturers transform warehouses into efficient, intelligent, and scalable operational centers.
Contact Person: Christina Zhou
Phone: +86 13918961232（Wechat ， Whats App）
Mail: info@everunionstorage.com
Add: No.338 Lehai Avenue, Tongzhou Bay, Nantong City, Jiangsu Province, China