An automated storage and retrieval system, or AS/RS, uses computers and robotics to store and retrieve goods without a person handling every pallet or carton. New Zealand operators are looking at automation now because land, building and lease costs are higher than ever;labour is harder to source and retain, and because growing order volumes are pushing manual systems past their limit.
AS/RS is not one product. It covers a range of technologies, from semi-automated shuttle racking through to fully automated mini-load, unit-load and vertical lift module systems, each suited to a different kind of inventory and a different scale of operation. Understanding the category as a whole, rather than a single system, is the first step to working out whether automation makes sense for a particular warehouse, and which type fits.
What counts as an AS/RS system
Any storage solution that uses robots, shuttles or cranes to move goods within a racking structure, controlled by warehouse management system software, counts as an AS/RS system. The common thread across every type is that a computer directs the movement of goods, rather than a forklift driver or picker doing it manually.
These systems typically handle receiving, storing, tracking, picking and dispatching, and they can run continuously without breaks, in the dark, and in cold storage conditions that would otherwise require protective measures for staff. The specific hardware varies considerably between system types, which is why comparing them side by side matters more than assessing AS/RS as a single category.
The AS/RS spectrum: comparing the main system types
Choosing the right AS/RS technology starts with matching the system to the goods being stored and the scale of the operation. The table below compares the main types available to New Zealand operators.
| System type | Typical goods handled | Storage density | Best-fit warehouse profile |
| Shuttle and satellite racking | Palletised goods, including cold store and freezer stock | High, with aisles as narrow as a single pallet width | High-volume palletised operations moving from manual to semi or fully automated handling |
| Mini-load AS/RS | Small parts, cartons, totes and bins | Very high for small item storage | E-commerce, spare parts and pick-heavy operations with high SKU counts |
| Unit-load AS/RS | Full pallets and large unit loads | High, with cranes serving tall, narrow aisles | Bulk distribution centres and manufacturers with consistent pallet flow |
| Vertical lift modules | Small components, tools and archived stock | Very high, using vertical building height rather than floor footprint | Sites with limited floor space but sufficient ceiling height |
Shuttle and satellite racking sits at the more accessible end of this spectrum, since it can be introduced as a semi-automated system before scaling to full automation. Mini-load, unit-load and vertical lift systems generally represent a bigger investment and a bigger commitment to automated operation from the outset. Storepro’s automated shuttle and satellite racking system is a common entry point for operators moving along this spectrum, though it is one option among several rather than the only path into automation.
The business case: when automation makes sense
Automation makes sense once the cost and risk of manual handling outweighs the investment required to remove it. Three factors tend to drive that calculation for New Zealand operators: labour availability, order volume, and the physical conditions goods are stored in.
Labour cost and availability is often the clearest signal. Businesses that struggle to source or retain warehouse staff, or that face seasonal spikes requiring short-term hires, gain real value from systems that reduce reliance on manual labour. Order volume matters just as much, since automated systems are built to move goods faster and more consistently than a person can sustain over a full shift. Cold storage and freezer operations add a further consideration, since automation removes the need for staff to work in conditions as cold as minus 27 degrees, which improves both safety and staff retention. AS/RS systems systems can lift floor space utilisation to as high as 90 percent and reduce the footprint needed for the same volume of inventory by half or more, which is the kind of measurable outcome that makes the investment case clear.
When automation is not yet the right call
Automation is not always the right next step, particularly for smaller or lower-volume operations where the capital cost outweighs the labour savings available. A warehouse handling modest, steady volumes with a stable team may get more value from a well-designed manual layout than from a robotic system it cannot fully utilise.
In these cases, reconfiguring the existing racking and layout often delivers most of the efficiency gain without the cost or complexity of automation. Storepro’s warehouse design and layout team can assess whether a manual upgrade meets the need now, while flagging the point at which automation would become worthwhile as the business grows.
Planning an automation project
An AS/RS project involves more than choosing hardware. The building itself needs to support the system, from floor loading and clear height through to power and network infrastructure for the controlling software.
Integration with an existing warehouse management system is one of the more technical parts of the process, since the AS/RS needs to communicate accurately with whatever software already runs the business. Timelines also tend to run longer than operators expect, covering design, procurement, installation and commissioning before the system is fully operational. Storepro’s project management team coordinates these stages end to end, while compliance facilitation manages the building consent process that applies to any significant racking installation in New Zealand.
How Storepro helps assess the right fit
Working out which AS/RS type suits a specific warehouse depends on details that are hard to judge from general research alone, including SKU profile, pallet flow, building constraints and growth plans.
Storepro’s warehouse consultants assess these factors directly, drawing on more than two decades of delivering both manual and automated racking solutions for New Zealand businesses. That experience means the recommendation that follows reflects what has actually worked on comparable sites, not just what the technology is theoretically capable of.
Wondering whether your warehouse is ready for automation?
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