Efficiency at Your Fingertips: Multi-Level Pick Modules Deliver Optimal Fulfillment and Picking Performance

Distribution center management is constantly asked to store, pick, and fulfill an increasing number of orders while raising the level and speed of service for customers. This is no small task, especially when faced with ever-mounting SKUs and a limited amount of space. Enter Pick Modules, a popular storage solution used to consolidate a large number of SKUs in a condensed warehouse footprint for streamlined order fulfillment. 

Pick modules are multi-level structures that integrate various types of storage racking, mezzanines and conveyor systems for high-volume case and split-case picking. Efficient pick module applications result in faster, more accurate order picking in less space, eliminating worker travel and search time. High-throughput distribution centers across e-commerce, wholesale beverage, foodservice, healthcare and 3PLs are prime candidates for pick module applications.

Pick Modules Advantages

Some of the most important advantages of pick modules include:

• Improved space utilization
• Increased pick locations 
• Worker safety isolated from powered vehicle traffic
• Cost savings compared to building expansion
• Enhanced picking efficiency, productivity & accuracy
• Reduced labor costs/travel time
• Increased throughput

How Do Pick Modules Work?

The types of conveyor systems, pallet rack and carton storage integrated within the pick module will vary depending on the facility’s inventory and fulfillment requirements. Typically, a combination of pallet rack equipped with pallet flow or push-back rack,  static shelving, carton flow, and conveyors make up a pick module. Cartons or individual items are typically picked from carton flow or static shelving onto a takeaway conveyor to be transported to packing and shipping.

Conveyors commonly used in pick modules include roller conveyors and vertical reciprocating conveyors. Virtually every type of conveyor can be used effectively in a pick module. …and more.

Storage Applications for Pick Modules

• Carton Flow – Cases or totes are loaded into carton flow racking located on either side of the central conveyor.  Carton flow is good for systems built for better SKU selectivity. Adjacent selective or push-back rack is often used to replenish the pick module’s carton flow lanes.  
• Pallet flow – Pallets are loaded into wheeled or roller lanes set at an incline flowing toward the center pick aisle. Full or split-cases are picked from the front pallet to the center conveyor with reserve pallet storage readily available in the pallet flow lane.
• Push-Back – Dynamic pallet storage often used on upper pallet rack levels to quickly replenish lower-level carton flow rack. 
• Static Shelving – Modular and relatively inexpensive, industrial storage rack is a dependable solution for piece and carton picking. Best for slower-moving SKUs that don’t require deep reserves better served with carton and pallet flow.

Conveyor Systems Used in Pick Module Applications 

Pick modules can also be used to accommodate virtually all types of conveyor systems. The types of conveyors integrated into the pick area will depend on inventory throughput and material flow requirements of the order picking operation.

• Roller Conveyor – Requires manual guidance (pushing) of cartons down the conveyor lane until they reach the end of the module or another type of conveyor within the module. 
• Powered Incline Conveyor – Ideal for bringing cartons from lower levels to higher levels within the module, powered incline conveyors can seamlessly take materials from pallet flow racking to carton flow with minimal human effort. 
• Automated Conveyor – Can offer increased SKU selectivity while expediting the processing of cartons from storage to picking
• Vertical Reciprocating Conveyor (sometimes referred to as freight elevators) – Ideal for multi-level picking and storage. Vertical reciprocating conveyors safely allow for the raising and lowering large volumes of cartons. 
• Spiral Conveyor – Ideal for high-throughput, high-speed workflow, spiral conveyors can load cartons up or down the module at speeds exceeding 200 RPM. 

Your pick module conveyor choice will be largely contingent upon your throughput needs, spatial restrictions and average inventory size and work-flow. 

Let WOI Design Your Facility’s Pick Module

If you’ve decided that a pick module is the best way to bring your storage and order fulfillment together into one unit, Warehouse Optimizers, Inc. is ready to help. We have decades of experience helping facilities just like your design pick modules that work for them. With our 5 Step Total Satisfaction Experience™ you are guaranteed that we listen and execute your project paying special attention to your particular application, project timelines, safety, and appearance of the finished product. We will walk you through each stage of the process and offer expert customer service and peace of mind. Contact a member of our team today and chat, Zoom, or call us at (865) 540-4004 for a prompt response. We proudly serve customers in Tennessee, Alabama, and throughout the Southeast.