Vertical Lift Modules
An automated vertical storage system that stores inventory on trays and retrieves them on demand — bringing product to the operator at an ergonomic pick window instead of sending the operator to find the product.
The Inventory Comes to You
A vertical lift module (VLM) is a self-contained automated storage system that occupies a compact footprint and uses available building height. Two columns of trays face each other with an automated inserter/extractor (I/E machine) traveling between them. When an operator requests an item, the machine retrieves the correct tray and presents it at an ergonomic pick window at the front of the unit.
The result: an operator can access thousands of SKUs from a single workstation without walking an aisle, climbing a ladder, or searching through bins. Retrieval time is measured in seconds.
VLMs are used where dense storage of small-to-medium items is required alongside fast, accurate retrieval — spare parts, pharmaceuticals, electronics, tools, apparel, and other high-value or high-mix inventory profiles.
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From Request to Pick in Seconds
VLMs are controlled by an onboard software interface that integrates with your warehouse management system. Operators request items by SKU, order, or pick list — the machine does the rest.
- Operator enters a pick request at the workstation terminal — by SKU, order number, or scan
- The I/E machine travels to the tray location, extracts the tray, and presents it at the pick window
- A light pointer or display indicates the exact bin on the tray for the required item
- Operator picks the item and confirms the quantity — system records the transaction
- Machine returns the tray to its optimal storage position automatically
- Inventory position, quantity, and access log are updated in real time
Six Operational Advantages
Dramatic Space Recovery
VLMs use building height instead of floor space. The same inventory that would fill a 1,000 sq ft shelving area can often fit in a VLM footprint of 150–200 sq ft — recovering floor space for other uses.
Fast Retrieval
Average tray retrieval time is under 30 seconds. Operators no longer walk to inventory — they wait at a workstation while the machine fetches it. For high-pick operations, the productivity gain is significant.
Pick Accuracy
Light-pointer guidance and system-confirmed quantities virtually eliminate mis-picks. The system only presents the correct tray and directs the operator to the correct bin — no searching, no misreads.
Secured Inventory
Inventory is enclosed within the machine and inaccessible without an operator credential. Every pick is logged with user, time, item, and quantity — creating a full audit trail for regulated or high-value inventory.
Ergonomic Pick Height
The pick window is positioned at a fixed, ergonomically comfortable height — eliminating the overhead reaching, floor-level bending, and ladder climbing that cause repetitive strain injuries in traditional shelving aisles.
Real-Time Inventory Visibility
The VLM management software maintains live inventory counts by SKU, location, and access log. Integrates with most WMS platforms to feed data upstream — or operates as a standalone inventory system.
Typical VLM Specifications
VLMs are configured to your building height, inventory profile, and throughput requirements. The ranges below represent typical configurations — your system is specified to your exact facility.
| Parameter | Typical Range | Notes |
|---|---|---|
| Height | 8 ft – 50+ ft | Configured to your clear ceiling height; maximizes vertical cube |
| Footprint | 70–250 sq ft per unit | Width and depth vary by model and tray size |
| Tray Capacity | Up to 1,100 lbs per tray | Individual tray load rated by model; total system capacity in tons |
| Tray Height Clearance | 2"– 24" (auto-optimized) | System adjusts tray spacing dynamically to maximize density |
| SKU Capacity | Thousands per unit | Depends on item size, tray configuration, and bin divider layout |
| Retrieval Speed | Under 90 seconds typical | Average retrieval under 30 seconds for mid-height configurations |
| Number of Units | 1 to multiple per facility | Units can be linked for multi-machine pick operations at one workstation |
| Power Requirement | Standard 3-phase | Electrical infrastructure included in Alloy's installation scope |
The Right Application Profile
VLMs outperform traditional shelving when you need density, speed, security, or ergonomics — or any combination of the four.
Spare Parts & MRO
High SKU count, low velocity per SKU, high cost per item. VLMs consolidate what would be hundreds of shelving bays into a fraction of the footprint, with full access control.
Pharmaceuticals & Medical Devices
Regulated inventory requiring lot traceability, access logging, and documented chain of custody. VLM software provides the audit trail compliance requires.
Electronics & High-Value Components
Enclosed, secured storage with per-user access credentials and complete retrieval logs reduces shrinkage and provides documentation for insurance and audit purposes.
Apparel & Retail Fulfillment
High-mix, small-unit inventory picked to order. VLMs enable a single operator to fulfill a wide product range quickly from a compact, ergonomic workstation.
Tools & Die Storage
Heavy, high-value items stored in controlled access. VLMs eliminate the need for dedicated tool cribs while providing faster retrieval and better inventory accuracy than manual systems.
Space-Constrained Facilities
Any facility where floor space is a constraint and ceiling height is available. VLMs convert overhead cubic footage — currently unused — into productive, dense storage capacity.