In a deep lane ASRS multiple rolls are stored in the same storing channel. The main benefit of deep lane storage system is a superior storing density and thus compact footprint.

Deep lane solutions can be implemented for products such as pulp bales, paper rolls, wire rod coils, and tires. In contrast, coil and sheet high-bay warehouses are typically designed as “single-deep” systems, where each storage position is accessed individually.

Pesmel handles heavy, bulky industrial products across three main industries:

• Pulp & Paper — paper and board rolls, pulp bales
• Metals — steel and aluminium coils, wire rod bundles, long products, and plates
• Tire — finished tire products

Pesmel also handles non-woven products such as fiberglass mat rolls. Individual products can weigh up to 40 tons, all managed through fully automated handling, sorting, storing, and shipping systems.

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High-bay ASRS systems maximize space by building vertically, reduce labor needs, and operate 24/7 with consistent precision lowering product damage and improving safety. Real-time inventory tracking eliminates stock discrepancies, while the direct connection between production and dispatch speeds up the entire supply chain.

Delivery time for an automated high‑bay ASRS is typically 1-2 years. The delivery duration varies by warehouse size, engineering scope, and customer requirements.

Pesmel provides full turnkey delivery — from pre‑engineering and simulation to installation and handover.

High‑bay AS/RS systems are relatively expensive due to their size, automation, and complexity, often requiring multi‑million investments. However, they deliver significant long‑term savings and efficiency gains, making them cost‑effective over time.

Typically, 5 years. ASRS ROI is mainly driven by labour reduction, space optimization and efficiency gains.

Yes, we do, since 1978 Pesmel has delivered over 600 automated storing, logistics and packing systems.
Read more about our references on our References page.

ASRS systems are project‑specific, ranging from compact installations to very large high‑bay structures depending on capacity needs, product types, and layout requirements.

Pesmel’s high‑bay warehouses are adjustable across all three axes—length, width, and height—with structures reaching up to 45 meters. This vertical capacity can reduce the required storage footprint by as much as 80% compared to traditional solutions. For future growth, the system can be extended longitudinally to increase capacity without redesigning the entire facility.

A freestanding ASRS is installed inside a separate building provided by the customer, while a rack‑supported building integrates the storage racking and the building structure into one engineered construction.

Yes — Pesmel’s ASRS solutions are fire safe, as fire‑protection systems are integrated directly into the storage structure. The automated storage includes sprinkler pipes installed on the racks at each level, providing built‑in fire‑suppression capability.

Pesmel’s ASRS scales for future needs by offering flexible, adjustable storage capacity that can handle different product types without redesigning the warehouse.

The high‑bay structure and automated stacker cranes allow capacity and functionality to be expanded or adapted as production volumes or product mixes change. The setup also allows for easy extension in length.

Pesmel ASRS is designed to handle rolls with different characteristics, organizing inventory SKUs according to product type, receiving them in random order and sending them out as required.

Products are available from ASRS to loading dock in under 20-25 minutes.

High-bay ASRS is a fully automated solution operating 24/7/365, it is designed to reduce staffing needs by up to 85%.

Pesmel’s automated high‑bay warehouses are designed to run with minimal human operators, typically limited to supervision with 1-2 operators.

Deep‑lane ASRS systems are typically optimized for high‑density storage, which often leads to LIFO behavior by default. However, in automated systems with WMS control, FIFO can be achieved by design.

Pesmel’s ASRS has very low energy consumption, because the system uses regenerative drives that recover braking energy and feed it back into the power grid, and it can be paired with rooftop solar panels to offset most of its operational electricity use.

Pesmel systems are always designed on a case-by-case basis, and a contingency plan is an integral part of the design process. It is always considered and planned for when engineering the system.

Pesmel validates ASRS performance before investment through a simulation of the entire material flow, using real customer data such as product dimensions, production plan and shipping schedule.

A Warehouse Management System (WMS) controls and optimizes warehouse operations and inventory in real time. It operates between business systems (ERP/MES) and shop-floor automation, coordinating execution. WMS improves performance by increasing throughput, reducing errors, optimizing space use, and enabling faster, data-driven material handling.

A Digital Twin is a real-time virtual model of physical operations, used across the project lifecycle: in sales to simulate and validate solutions, in development for virtual commissioning and operator training before go-live, and in production to predict near-term behavior and support daily decisions. It optimizes operations by reducing risk and ensuring decisions and changes are proven before execution.

Coil rust protection is ensured through fully automated through‑eye wrapping (TEW) technology, which creates an airtight package using crêpe paper to absorb internal moisture and PE film to block external humidity. This automated process provides high‑level moisture protection without VCI chemicals.

More information can be found on our Coil packing -page.

Coil mechanical protection is ensured through automated mechanical protection steps such as body wrapping, edge protections, headers, and strapping, all applied automatically according to the required packing code.

The correct protection level is chosen based on handling frequency and transportation method, ensuring the coil stays undamaged during handling, storage, and transport.

More information can be found on our Coil packing -page.

Automatic packing provides higher capacity, lower material costs, and safer, more consistent packing quality. It reduces labor needs, eliminates manual dangerous steps, and optimizes material usage by cutting packing materials to the correct size automatically.

The packing capacity is ca. 20 coils per hour on a fully automatic packing line, depending on the packing code.

A fully automated packing line requires two operators: one for supervision and one for material supply.

Pesmel provides comprehensive lifecycle support and maintenance for automated high‑bay warehouses, including:

• 24/7/365 remote HelpDesk for urgent issues via secure connection
• Regular preventive maintenance (mechanical, electrical, PLC, ICT) to ensure high availability and long system life
• WMS/YMS application maintenance, including backups, updates, priority support, and online training
• Spare parts service with new parts to ensure reliability and minimize downtime
• Modernizations and upgrades for aging systems to improve throughput, safety, and automation level

For further questions, please do not hesitate to contact our customer support.