URBX Robotic Storage System Delivers 500 Cases or Totes Per Hour Per Robot, Reaches 125 Feet High, and Eliminates Traditional Aisle RequirementsWIXOM, MI – October 8, 2025 – Integrated Systems Design (ISD) announces the launch of its URBX automated storage and retrieval system, a Cube robotic ASRS system that fundamentally changes how distribution centers, warehouses and manufacturers operations approach high-density storage and rapid fulfillment.The URBX Cube Robotics ASRS system addresses three critical pain points facing warehouse operators: insufficient floor space, unsustainable labor costs, and inadequate throughput capacity to meet ecommerce and omnichannel delivery demands."Traditional ASRS systems require aisles for cranes or forklifts. This robotic cube system eliminates that waste," states Bob Jones, Senior Analyst and Consultant at ISD. "You're storing inventory in what used to be empty air. That matters when you're paying $15 per square foot."The Floor Space Problem Gets WorseDistribution centers and warehouses face a fundamental constraint—they're running out of room. Adding square footage increases inefficiencies and wastes valuable time. Industrial real estate rates continue climbing. Building new facilities takes 18-24 months and requires capital expenditures that strain budgets.Meanwhile, inventory requirements increase. SKU proliferation forces warehouses to stock more items in more variations. Ecommerce returns add to storage demands. Safety stock levels rise to buffer against supply chain disruptions.The math doesn't work. You need 40% more storage capacity but can't expand your footprint. Traditional solutions—racking configurations, mezzanines, off-site storage— don't solve the core problem."We've seen operations store inventory in trailers parked in their lots," Romaine explains. "That's not a storage strategy. That's desperation. You can't efficiently pick from a trailer 200 yards from your packing stations. I’ve seen a facility that parked trailers permanently at non-essential dock doors and just kept the doors open and utilized it as storage. This creates hazards and congestion and simply indicates a much larger problem… lack of floor space."How URBX Cube Robotics ASRS Changes the EquationThe new ISD URBX Cube robotic ASRS operates on different principles than conventional crane and aisle and other Cube automated storage systems.Instead of using cranes moving through fixed aisles, autonomous robots traverse a three- dimensional grid structure. They climb vertically and move horizontally without dedicated travel lanes. Each robot accesses any storage location within the grid. The system stores totes in a dense Cube arrangement—eliminating the wasted aisle space that traditional ASRS requires.The storage density improvements are significant. A Cube robotic system typically achieves 3-4 times the storage capacity of conventional racking in the same footprint. The system reaches heights up to 125 feet—utilizing vertical space, which most facilities leave empty.Each robot handles up to 100 pounds and completes up to 500 presentations per hour. That's 1000 transactions hourly when counting both storage and retrieval operations.Multiple robots work simultaneously within the same grid structure, scaling throughput based on demand."Think of it as three-dimensional chess," notes Ed Romaine, VP Marketing and Business Development at ISD. "The robots know where every tote or case sits. AI-driven software constantly optimizes their pathways.They're storing popular SKUs in easily accessible locations and moving slow-movers to deeper positions—automatically, continuously, without human intervention."Technical Specifications That MatterThe system's capabilities address real operational requirements:Storage Performance• Handles cases and/or totes• Maximum height: 125 feet• Load capacity: up to 100 pounds per tote• Tote or case handling rate: 500 per hour per robot• Transaction rate: 1000 storage/retrieval cycles per robot hourly• Tote and case dimensions: accommodates 6-inch to 24-inch containers for maximum flexibilityIntegration Capabilities• Compatible with standard conveyor systems• Interfaces with warehouse management software (WMS), warehouse control systems (WCS) and/or warehouse execution systems (WES)• Integrates with existing pick-to-light and goods-to-person technologies• Integrates with palletizers and outbound shipping systemsOperational Features• Machine learning algorithms optimize robot tasking and routing• AI-driven grid technology maximizes throughput• Vision systems detect dimensions, anomalies, and barcodes• Redundant robot fleet ensures continuous operationSystem Architecture• Modular design allows phased implementation• Scalable configuration grows with business requirements• Fault-tolerant operation continues during individual robot maintenance• Remote monitoring enables predictive maintenanceReal-World ApplicationsThe Cube robotic ASRS serves multiple industries facing storage and throughput challenges.Ecommerce operations benefit from rapid order fulfillment speeds and high inventory visibility. The system handles split-case picking efficiently—a critical requirement for direct-to-consumer fulfillment.Case handling applications allows organizations to cost-effectively store, sequence, buffer, stage, and retrieve cases automatically without any human intervention.Retail distribution centers use the technology for omnichannel order processing. The same system fulfills store replenishment orders and individual customer shipments without reconfiguration.Third-party logistics providers leverage the system's flexibility to serve multiple clients from shared facilities. They reconfigure storage allocations quickly as customer requirements change.Pharmaceutical distributors appreciate the system's accuracy and inventory control capabilities. The technology provides real-time location tracking and supports first-expired-first-out (FEFO) picking strategies.Electronics manufacturers utilize the system for component storage and kitting operations. The high-density storage accommodates thousands of low-volume SKUs in minimal floor space."One automotive parts distributor we worked with needed to double their SKU count without expanding their building," Romaine states. "Traditional racking couldn't deliver that. The Cube robotic system gave them 3.5 times their previous storage capacity in the same footprint. They canceled a planned facility expansion that would have cost $12 million."URBX Cube Robotics ASRS Implementation ApproachISD's OptimalOps-Process framework guides Cube robotic ASRS implementations from initial assessment through system validation.The process starts with comprehensive data analysis. ISD examines order profiles, SKU velocity, inventory characteristics, and workflow patterns. This analysis determines optimal system sizing and configuration.Design work considers both upstream and downstream operations. The Cube ASRS doesn't operate in isolation—it connects to receiving processes, picking workstations, packing stations, and shipping sorters. ISD designs these integration points for seamless material flow.Implementation planning addresses operational continuity. Most facilities can't shut down for system installation. ISD develops phased deployment strategies that maintain operations during construction and commissioning.Training programs prepare staff for new workflows. Technology changes how workers interact with inventory. Comprehensive training ensures smooth transitions and rapid productivity ramp-up."The technology works beautifully—when it's implemented correctly," Romaine emphasizes. "Poor integration kills ROI. We've seen expensive systems underperform because nobody thought about how totes move from receiving to the ASRS input, or how picked orders flow to packing stations. You need integrators who understand the entire workflow, not just the equipment."Return on Investment Factors for URBX Cube Robotics ASRSCube robotic ASRS investments typically deliver ROI through multiple operationalimprovements:Labor Reduction Manual picking requires workers to travel, search, and retrieve items. The Cube system brings inventory to stationary picking positions. Labor productivity typically improves 3-4 times compared to manual operations.Space Optimization Increased storage density eliminates expansion requirements.Organizations avoid capital expenditures for building additions or new facilities. Some operations consolidate multiple locations into single automated facilities.Accuracy Improvement Automated storage and retrieval eliminates location errors. Vision systems verify tote contents. Pick accuracy typically exceeds 99.9%—reducing returns, customer complaints, and reshipment costs.Throughput Capacity The system scales throughput by adding robots to the grid structure. Organizations handle peak volumes without temporary labor surges or overtime expenses.Inventory Visibility Real-time location tracking provides accurate inventory data. Organizations reduce safety stock requirements and improve inventory turns."One Ecommerce operation calculated their payback at 22 months," notes Romaine. "They eliminated 18 picking positions, gained 12,000 additional pallet positions, and improved order accuracy from 98.1% to 99.7%. Those aren't hypothetical benefits. They're documented results measured six months post implementation."Why ISD as Your URBX Cube Robotics ASRS Integration PartnerISD brings 60-plus years of warehouse automation experience to Cube robotic ASRS implementations. The company's OEM-agnostic approach ensures clients receive optimal solutions rather than vendor-locked specifications.ISD's expertise extends beyond equipment installation. The company analyzes entire facility operations—from receiving through shipping—designing integrated solutions that maximize performance across all processes.The OptimalOps-Process framework provides systematic methodology for assessment, design, implementation, and validation. This structured approach minimizes risk and accelerates time to full productivity.ISD maintains relationships with leading material handling equipment manufacturers. This network provides access to proven technologies and ensures long-term support availability."We're integrators who happen to manufacture some products—not manufacturers trying to be integrators," Romaine concludes. "That difference matters. We recommend Cube robotics if it's the right solution. We recommend other technologies when they fit better.Your operational success is our success. We're partners, not vendors."For organizations evaluating automated storage solutions or seeking to optimize existing warehouse operations, ISD offers free consultations to assess operational performance and identify improvement opportunities.About ISD - Integrated Systems DesignISD is a leading systems integrator specializing in warehouse, distribution, and manufacturing operations, as well as an OEM provider of the UltraStore Mid-Load ASRS system. Our proprietary OptimalOps-Process™ features an 8-step framework designed to enhance operational efficiency, reduce costs, expedite ROI, and future-proof operations by optimizing picking, sorting, packing, and shipping processes.At ISD, we prioritize collaboration, working closely with clients to define objectives, conduct comprehensive data analyses, and implement strategic planning. This partnership creates high-performance, tailored solutions that align with operational and business KPIs.Our extensive offerings encompass conveyor systems, Automated Storage and Retrieval Systems (ASRS), Autonomous Mobile Robots (AMRs), robotics, sortation systems, warehouse software, pallet handling, packaging automation, and order fulfillment technologies.With 60-plus years of experience and an OEM-agnostic approach, ISD delivers customized solutions that maximize ROI and operational effectiveness. For more information, visit www.isddd.comVideo Link: https://youtu.be/vfHuAcZZpNQContactEd RomaineChief Marketing Officereromaine@isddd.com.

WMC’s Poster Showcases Diversity of Wisconsin’s Manufacturing SectorMadison, Wisconsin — October 14, 2025 — Wisconsin companies sold over $209 billion in manufactured goods last year, accounting for just under 20 percent of the state’s GDP. But too few Wisconsinites know about the diversity of this production powerhouse, the state’s largest business association argues. A new poster, developed by the group, seeks to change that.Wisconsin Manufacturers & Commerce (WMC), the combined state chamber of commerce and manufacturers association, released a Made in Wisconsin poster featuring 51 items manufactured or produced in Wisconsin. WMC, in partnership with BMO, unveiled the poster to promote and celebrate the state’s largest industry ahead of Manufacturing Month in October.“Manufacturing is Wisconsin’s economic super sector,” explained Kurt R. Bauer, WMC President & CEO. “Wisconsin’s nearly 9,000 manufacturers generate $73.7 billion in economic activity each year.”Bauer said that nearly 480,000 Wisconsinites, or one in six, work directly in manufacturing.“These products represent the high-wage, high-skill, high-tech careers these manufacturers provide in our communities,” Bauer said. “We hope the poster will make Wisconsinites beam with pride in learning what’s made by their own neighbors.”Included on the poster are household names and globally distributed products, such as ORBIS® Corporation, a global leader in reusable packaging solutions headquartered in Oconomowoc, and Neenah-based Menasha Packaging, a leading provider of innovative graphic packaging, retail display and supply chain solutions. Both companies are part of Menasha Corporation, a 175+ year-old, family-owned company and share a commitment to driving efficiency and innovation across the supply chain.“Every month is Manufacturing Month as far as we’re concerned,” said Norm Kukuk, president of ORBIS Corporation. “Helping world-class companies move their products safer, faster, more cost-effectively and more sustainably all starts in Wisconsin. I couldn’t be more proud of how our people innovate with purpose, delivering sustainable, reusable packaging solutions that enhance supply chain performance and reduce environmental impact.”“Wisconsin has been home to Menasha for nearly two centuries and our legacy is closely connected to the state,” said Menasha Packaging Company President Mike Riegsecker. “We’re forever grateful how the people of Wisconsin have helped support our ongoing commitment to transformation and modernization.”While highlighting just a tiny fraction of what’s produced in Wisconsin, the poster nonetheless shows off the Badger State’s manufacturing prowess. The poster will be shared with elected officials, local chambers, education partners, and more.“We’re incredibly proud of the strength, diversity, and innovation of our state’s manufacturing sector,” said Dave Anderson, BMO WI Head of Commercial Banking. “As we head into Manufacturing Month, we’re proud to partner on this year’s Made in Wisconsin poster to showcase just a small sample of the incredible things made right here in Wisconsin.”About ORBISWith more than 170 years of material handling expertise and 65 years of plastics innovations, ORBIS helps world-class customers move their product faster, safer and more cost-effectively with reusable totes, pallets, containers, dunnage and racks. Using a unique approach, ORBIS experts analyze customers’ systems, design a solution and execute a reusable packaging program for longer-term cost savings and to meet and achieve their sustainability initiatives and goals. Using packaging life-cycle assessments to compare reusable and single-use packaging, ORBIS helps customers achieve longer-term cost savings while minimizing their overall environmental impact. ORBIS is a part of Menasha Corporation, one of the oldest family-owned manufacturers in the United States. As a steward of sustainability, ORBIS is committed to a better world for future generations. Headquartered in Oconomowoc, ORBIS has more than 3,100 employees and almost 50 locations throughout North America and Europe. For more information, please visit orbiscorporation.comContactSamantha GoetzMarketing Communications Managerinfo@orbiscorporation.com262-560-5449

High-quality gear motors from NORD DRIVESYSTEMS are a crucial piece of the manufacturing puzzle for this Georgia-based automation provider.Consider the following scenario: guided by vision sensors, a robot spots a product on a moving conveyor, determines its exact position and, in one fluid motion, picks it up and places it into a waiting assembly, carrier tray, or shipping container. What human operators once found tiring—or at least tedious—the robot performs flawlessly, hour after hour, even long after its flesh-and-blood coworkers have gone home for the evening.Given the ongoing shortage of skilled workers, we can expect to see many more such scenarios, especially as the U.S. ramps up its reshoring efforts. That's where John London, Director of Operations at MESH Automation, comes in. "Getting parts and products positioned precisely without fail—there's little room for error," he says. “That’s long been one of the primary challenges with many competing automation systems. But not for us.”Since its founding in 1999, MESH Automation of Dawsonville, Georgia, has been meeting these and other automation challenges head-on. The company designs and builds robotic palletizing, machine tending, material handling, and warehouse control systems for an eclectic mix of customers across practically every industrial manufacturing sector.Whether they’re building solutions for automakers and their tier suppliers or food processors, roofing material producers, fertilizer manufacturers and many others, MESH and its 40+ employees work to provide robust and reliable automation systems by focusing on craftsmanship, attention to detail, and commitment to excellence.Proud PartnershipsPart of this success stems from strategic partnerships with some of the leading names in automation. These include FANUC, Siemens, and Cognex, to name a few, all of which contribute to MESH Automation's reputation for quality and dependability. But with automation comes the equally important need to bring products and materials to and from the machine tool, packing station, or inspection system, and do so without fail.For this critical task, MESH depends on a supplier with equivalent recognition throughout the industry: NORD DRIVESYSTEMS. “I like to tell people that, even though we build conveyors, we're not a conveyor company,” says London. “Still, we make a lot of them, and pretty much all are located within 30 feet or so of a robot.”For the past three years, he adds, each of these conveyors has used NORD helical worm gear motors tomove whatever’s sitting on top of it.This particular partnership began thanks to a COVID-induced supply chain disruption; after MESH Automation’s previous gearmotor supplier ran into inventory problems, London and his team reached out to their distributor, Motion Automation Intelligence of Birmingham. The sales representative there suggested they give NORD a try. Unfortunately, the very first shipment hit a snag—the motors arrived damaged in transit."That's when I knew NORD would be a good company to work with," London says. “Their standard lead time was six weeks at the time, but they were able to deliver replacement motors in just two, keeping us on schedule. That told me a lot about their emphasis on customer service.”This support level continues to this day. In one recent example, a MESH apprentice accidentally wired three motors incorrectly, causing them to burn out during startup. After being notified of the situation, NORD's Charlotte plant prepared replacements within a few hours, allowing a MESH project manager to pick them up that afternoon. "That was a big deal for us, and it reinforced what I already knew: NORD DRIVESYSTEMS is a solid company, as is our relationship with them," London says.Diverse NeedsThe partnership with NORD has served them well. As noted earlier, MESH enjoys a diverse customer base, with no industry segment exceeding 25% of its business. “We don't want just one industry feeding us," London explains. "Despite their differing needs, however, we're able to cost-effectively deliver automated systems to each of these industries due to our use of pre-engineered platforms, which we can easily modify for specific applications.” He laughs. “No two are identical, although we do use terms around here like 'half identical’ and ‘three-quarters identical’ to describe the level of customization needed to meet customer requirements.”NORD helps in this respect as well. For instance, MESH technicians can quickly change the gear ratio on any motor, a normally onerous chore made possible by NORD's modular, interchangeable components. This flexibility allows them to easily adjust the speed and torque to match the application without having to stock additional components. And when a special order is called for, notes London, "They've pretty much had whatever we need in stock or available within a couple of weeks."Whatever the customization level, these platforms often fall under the “MAC” family of automation cells—the MACTend for machine tending, the MACPac for packaging tasks, the MACGrind for finishing small- to medium-sized parts, and so on. Together with its assortment of process-specific “bolt-on” modules, each offers a starting point for MESH engineers to design what are effectively custom solutions but without the associated price point.Prove ItAmong the many customer success stories posted on the company website is a manufacturer of carpet tiles, which needed to feed "master" tiles to a press that cuts them into smaller pieces, a step known as "planking." Here, MESH delivered a cell containing a pair of vision-equipped robots and custom end-of-arm tooling ableto replicate the delicate but ergonomically taxing motions of a human operator.In another, a company that constructs hurricane-proof sheds wanted an automated way to screw the wall and roof panels to the wooden frame. In the past, this operation proved both labor-intensive and error-prone. Yet MESH designed a system with two robots, each armed with a screw gun to fasten the panels, following pre-programmed paths and working around window and door openings while ensuring consistent attachmentquality.And a company supplying machined components to its automotive customer desired to augment its human workforce by going “lights out” for three days at a time. This endeavor wouldn't be notable except for the fact that two different castings were used to produce six different part numbers, which meant that the system had to be "smart" enough to identify each workpiece before loading it into the CNC lathe. MESH accommodated this requirement by integrating a vision inspection system into the cell, reading each casting number and tracking it both during and after machining.Each of these solutions and many others share a common theme: the need for dependable conveyors to move products, parts, and materials into and out of the cell. Without them, nothing happens, which is why the company continues to rely on NORD products, despite their being a bit more expensive than those of the previous supplier.Says London, “We buy around seventy NORD gear motors each year and are actually paying slightly more than we did before, but the partnership we've built is well worth the extra money. We’re not one to beat someone up on price and then run away when there's an issue—instead, we place great value on suppliers who offer a fair price and stand behind their products. That’s what NORD does.”Fast MoversMESH's latest project may be its most ambitious yet: a robotic induction system for e-commerce sortation, which debuted at the recent ProMat 2025 trade show. The system uses a vision-guided robot to pick items from bins, scan barcodes on either side of the box, package, or envelope, and place each on a high-speed conveyor feeding a bomb bay-style sorter. Here again, the system depends on NORD worm gear motors to keep everything moving.London notes that the scanning capability eliminates a key limitation of current systems, where operators must place items with barcodes facing upward. “Our system doesn't care which way the label faces. It also picks 1,800 items per hour—well beyond what a human operator can achieve. We think it’s the first such solution on the market.”When asked a question that’s at the top of mind for many—whether automation is putting people out of work—London pushes back. “Our robotic cells don't replace people—they move them to better jobs. For example, I’ve seen how the companies that implement automation can often expand their quality control efforts. They put more energy into making sure products meet higher standards. And because workers no longer have to perform the repetitive, oftentimes strenuous tasks common in manufacturing, they’re able to spend more time on process improvement, oversight, and other value-added activities. It's better for everyone involved and makes the company more profitable to boot. That's what automation delivers.”About NORD DRIVESYSTEMSWith more than 4,900 employees, NORD DRIVESYSTEMS has been developing, producing, and selling drive technology for over 50 years, and it is a global leader among full-service providers in the industry. In addition to standard drives, NORD delivers application-specific designs and solutions for special requirements, such as energy-saving drives or explosion-protected systems. NORD has subsidiaries and sales partners in 80 countries worldwide. The dense sales and service network guarantees optimal availability, enabling short delivery times, and customer-oriented service. NORD produces a very diverse range of drives for torques from 88 lb-in to more than 2.5 million lb-in, provides motors in the power range of 0.16 – 1,341 hp, and manufactures frequency inverters with the required power electronics of up to 200 hp. Inverter solutions are available for conventional control cabinet installations as well as for decentralized, fully-integrated drive units. Visit nord.com.ContactArielle SPOTTS608-850-1444Arielle.Spotts@nord.com

For warehouses and distribution centers, Destuff-it™ portable ergonomic conveyors provide a safe and efficient solution for handling floor-stacked packages in shipping containers or related vessels.

Stihl dealer in the Midwest can expect fast, accurate service when they need equipment, accessories or spare partsMississippi Valley Saw was founded in 1978 by Bob Joynt in Peoria, IL. It began serving the nation’s heartland by shipping chain saws, log splitters and accessories to about 70 independent dealers and lawn centers. Growth was swift, and in 1981 the company moved into a new location. Soon after, Mr. Hans Peter Stihl visited and asked them to drop all other lines and become an exclusive Stihl dealer. Mississippi Valley Stihl (MVS) was born.MVS investigated all possible solutions to their time, inventory and space issues and chose the Lean-Lift® Vertical Lift Module from Hänel Storage Systems. A bank of three units were installed initially, with a fourth lift added shortly after to keep pace with demand.The benefits of the Lean-Lifts® were immediate. Before the lifts, five or six people would work well into overtime to fill the day’s orders.After the lifts, a single person could get all orders received by 2 p.m. out by 4 p.m. the same day. Orders are picked faster with less walking and no more overtime.The lifts work together to cue the next part automatically so that the operator can move from lift to lift, minimizing any potential wait time for trays to be delivered to the access point. Totes and boxes are used to collect the various parts for each order, with a put-to-light system ensuring the right parts go into the right container. A pick-to-light system is used to pull fast moving items from bins nearby.The increased speed and accuracy afforded by the Hänel Lean-Lifts® allowed MVS to keep its commitment to its dealer network to provide the right part within 24–48 hours, even while stocking an ever-increasing inventory of parts.

The Hänel Lean-Lift as a high-speed shipping systemWhen it comes to tools, the experts at Productivity Inc. can provide customized solutions for the metalworking industry. In addition to consulting, customer care, service and maintenance,Productivity Inc. delivers tools and tool holders to customers throughout North America. Fast shipping from the company’s site in Minneapolis is supported by three Hänel Lean-Lifts® that are used to store more than 10,000 items.The Hänel vertical lifts are equipped with multifunction containers, making them ideal for automated small parts storage. Job orders are displayed directly on the HänelSoft® terminal and can be processed there.The high-speed version of the Hänel Lean-Lift® quickly brings stored items to the retrieval area on request.If the items needed for a particular order are located in various lift systems, picking performance can be boosted even more through parallel system operation.Thanks to digital compartment and sub-level indicators, even storage positions in very small configuration layout patterns can be identified easily. The combination of all these features ensures that orders are filled and shipped in record time – without errors.Orders are filled directly opposite the system access points, where they are also packed for shipping. Order confirmation is entered in the systems using barcode scanners. Another Hänel Lean-Lift® located in a different area of the warehouse is also integrated in the storage solution.Productivity Inc. quickly recognized the high quality of Hänel technology through the reliable performance delivered by the storage systems

The Protective Guarding Manufacturers Association (ProGMA) have developed a new American National Standard to provide guidance and a standardized test methodology for steel mesh containment panels (also known as rack guarding or rackback).Items stored in pallet racks have the potential to fall into aisleways, causing injury or damage. Steel mesh containment panels can be installed on storage racks to keep items from falling.ANSI MH31.1-2019, Steel Mesh Containment Panels Used in Pallet Rack and Vertical Storage System Applications: Performance and Testing Requirements, has been developed to provide guidance on containment panel design, use, and performance criteria, including a uniform testing methodology for evaluating restraint performance. and testing. This standard also addresses flue space requirements outlined in NFPA 13 for back-to-back storage rack applications.Information on ANSI MH31.1 and a list of manufacturers of steel mesh containment panels is available at www.mhi.org/progma.

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The Protective Guarding Manufacturers Association (ProGMA) has published a blog to supplement its latest video on safety at pick modules. The video can be viewed at mhi.org/progma/videos.Here at ProGMA, we have produced a series of educational videos on protective guarding equipment in the material handling industry. ProGMA members provide fixed protective guarding products to protect personnel, equipment, and inventory in industrial facilities. A variety of such items are designed for installation at pick modules, which are multi-level structures typically constructed out of pallet rack that allow multiple pallets of product to be stored, broken down, picked, and packaged into specific orders for shipping.Our video is targeted at end users, system integrators, material handling warehouse design consultants / engineers, distributors, and safety professionals in manufacturing and distribution centers in the material handling industry, as well as students studying the sector. Many household and industrial goods we interact with every day were once stored or passed through a pick module. At the distribution centers of companies like CVS Pharmacy and Rite Aid Corporation, for example, goods are stored before being repackaged and shipped to individual stores.As the 2:23min-long video says at the outset, pick modules can have several elevated levels of materials that are handled by both automation and personnel. Although everything in the material handling industry is becoming more automated, separation of full stored cases into smaller, individual shipments is still being completed manually. The size of pick modules has been increasing over the years; in the past, you may have seen a floor plus one level system, then a floor plus two levels, and now it is not uncommon to see three or even four elevated levels. This increases potential hazards.As the video continues, it is of paramount importance that proper guarding is used from the ground up to protect structures, the product they hold and, most importantly, the people working within and around them. Rack upright columns can be difficult to replace and costly to repair because often the area has to be closed off, product has to be removed, and multiple sections need to be disassembled. These components are all dependent upon one another, so if one part fails, the entire system can fail.The video highlights three “easy and affordable” solutions: Free-standing pallet rack column protectors Post cushions Bumper guardsHowever, ProGMA members offer a variety of products for ground-level protection including guardrails, bumper guards, column protectors, bollards, rack guards, and product containment enclosures  (i.e., wire mesh or netting); and for upper-level protection, such as side and back product containment enclosures (wire mesh or netting) to prevent products from falling below.What does ANSI say?The video continues, and quotes American National Standards Institute (ANSI) 6.4.3, which states that “…any gate that provides an access opening through the guards for the purpose of loading and unloading material onto a work platform shall be designed such that the elevated surface is protected by guards at all times. Gates that swing open, slide open, or lift or leave an unprotected opening in the guarding are not acceptable.”However, it is important to note that there are many mezzanines that were installed before the ANSI standards were created that used more conventional gates, such as removable, sliding, or swinging systems—and that is the same for pick modules. Systems can be retrofitted to achieve conformity with current standardization. There is no grandfather clause for ANSI (or OSHA) so all systems whether new or old should follow their guidelines. Note that many of the protective guarding products found in the video and on the ProGMA site are easily retrofittable to these older systems.As the video stresses, only dual-gate systems should be used. The same gates used on a pick module are also the preferred method for securing all elevated pallet drop areas whether they are in pick modules, on mezzanines, or on elevated work platforms such as storage or production / blending areas. The ANSI standards that recommended the use of dual-gate systems were written specifically for elevated work platforms and since a pick module is a type of elevated work platform that should be applied.The video demonstrates how a dual-gate system uses two counterbalanced and interconnected gates that are configured so when the first gate at the ledge is open, the second gate behind the pallet is closed. Fixed guarding on the sides—often the frame of the pallet rack in a pick module—prevents access into the side of the areas. This allows material to be loaded into the area while keeping employees a safe distance from the ledge and the material. When the rear / operator gate is opened, the ledge gate automatically closes, maintaining a barrier at the ledge while the pallet is accessed and picked. This creates what ProGMA calls a controlled-access area so there is always a barrier between the worker and the ledge.For information, ProGMA members that manufacture such solutions include Mezzanine Safeti-Gates Inc., Wildeck, and Heartland Engineered Products. Although companies still provide swing gates for pallet drop areas where a single pallet is loaded and staged, they are not an acceptable solution according to ANSI and could potentially create a situation where they are in violation of OSHA code.A self-closing swing gate, also featured in the video, should only be used when integrated with pallet flow lanes where multiple pallets are loaded into the system. The pallet flow lanes are pitched so the pallet rolls into the storage area. This allows the gate to immediately close once the pallet is loaded.  By comparison, when used for a single pallet position without flow rails, the staged pallet would hold the swinging gate open, preventing it from closing.For securing multiple deep pallet flow lanes, a dual-gate system is the preferred safety method because not only does it make sure a barrier is in place all times for fall protection, but it also keeps people out of the pallet flow lanes when pallets are being loaded. The two types of incidents we see in these areas are falls from the ledges and pallets being pushed into the legs of employees who have entered the lane. Only the dual-gate system keeps people out of the lanes when the lane is being loaded. The self-closing swing gate, however, does secure the ledge for fall protection.Hand in gloveOftentimes, a safety aspect can be used to increase productivity. For example, the self-closing swinging gate on pallet flow lanes will allow pallets to be quickly loaded into the system. Any time the lift truck operator wants to load a pallet into the area, they just push the pallet through the swinging gates. The dual-gate system has the potential of the gates being in the incorrect position for loading, meaning that the ledge gate is closed when the lift truck is trying to replenish pallets into the area. So they can go to load but a barrier is in place preventing them from doing so.A user can power operate these gates for remote operation but often this isn’t feasible due to the number of areas. Manual operation can actually create a safer and faster environment. The position of the gates in a dual-gate system can be used as a signal between the picker up on the platform and the lift truck operator below. In other words, when the ledge gate is closed that means the picker is picking from the pallets or the area doesn’t need to be replenished.When the picker has finished in that bay or when they notice the pallets need to be replenished in that bay, they just manually close the gate near them, which opens up the ledge gate. Now the lift truck operator can look up and see which areas are safe and ready to be replenished. This is an example of a safety system helping communications among the different workers.In conclusion, it’s evident that, despite automation, people remain at the center of activity in and around pick modules. ProGMA and its members are a one-stop-shop for leading safety solutions, whether it be for preventing hazards associated with falling boxes, product, or workers; or structural protection of the system itself from impact. As the video serves to reiterate, even in automated systems there are still people moving around the facility, either on ground level or on the elevated levels. Even if people are not used for the picking of material, there are areas where empty pallets or totes are removed that need to be guarded.The product-centric video doesn’t feature specific brands, but free-standing pallet rack column protectors, post cushions, and bumper guards are available from ProGMA members including Adrian’s Safety Solutions, A-Safe USA, Bluff Manufacturing, Boplan, DamoTech, Folding Guard, Husky Rack & Wire, Heartland Engineered Products, Jesco, McCue, Slowstop Guarding, SpaceGuard Products, Steel King, Troax, VisiPlas, Wildeck, and WireCrafters.Costs range from inexpensive, light-duty products to more expensive, heavy-duty solutions. Importantly, talking with the manufacturer about the application will help source the right product/s for the facility. No two pick modules or applications are completely alike and that’s what the member companies of the ProGMA are here to help with.The ProGMA website—mhi.org/progma—features details of 22 member companies and hundreds of solutions to help companies with older systems find protective guarding solutions to update / upgrade their pick module system.See the latest video and others in the series at mhi.org/progma/videosShould you be using a ProGMA member to enhance the safety and productivity of your pick modules?About ProGMAThe Protective Guarding Manufacturers Association (ProGMA) members are the industry’s leading suppliers of fixed protective guarding products designed to protect personnel, equipment, and inventory in industrial facilities. Member companies meet regularly to review, discuss, and revise the standards for design and performance of protective guarding products used in the material handling industry. ProGMA member companies are committed to the development, maintenance, and publishing of industry standard specifications for these systems. Visit the website at mhi.org/progma.About MHIMHI is an international trade association that has represented the material handling, logistics and supply chain industry since 1945. MHI members include material handling and logistics equipment and systems manufacturers, integrators, consultants, publishers and third-party logistics providers. MHI offers education, networking and solution sourcing for their members, their customers and the industry as a whole through programming and events. The association sponsors the ProMat and MODEX expos to showcase the products and services of its member companies and to educate manufacturing and supply chain professionals.Contact for editorial enquiries: Ashley Skidmore, askidmore@mhi.org or 704-676-1190

Price: $50.00This standard is established to provide a guideline for design, testing, fabrication, and utilization of industrial storage rack decking utilized as an accessory for industrial steel storage racks that conform to ANSI MH16.1, Design, Testing, and Utilization of Industrial Steel Storage Racks. Storage rack decking is placed on beams of industrial steel storage racks to create a surface on which to place materials that can be on pallets, in containers, or in some other form.This standard applies to uniformly loaded storage rack decking applications, as well as various concentrated and partially distributed loading conditions common to storage rack applications. Storage rack decking can be fabricated from welded-wire mesh with permanently attached reinforcements, metal bar grating, composite engineered wood, corrugated metal, perforated sheet metal, or other materials that meet the performance requirements for use in storage racks.This standard does not apply to:Storage rack decking manufactured prior to date of adoption of this standard;Storage rack decking that has been improperly installed, altered, damaged, or used in any manner other than that for which it was originally intended, designed, purchased, sold, or a combination thereof;Lumber not graded or stamped by the Southern Pine Inspection Bureau (SPIB), West Coast Lumber Inspection Bureau (WCLIB), or equivalent grading agency; orStorage rack decking that is intended to support any loads other than product loads (e.g., moving, or live, loads due to walking or stepping).

Price: $50.00The purpose of this standard is to serve as the guide for designers, manufacturers, sellers, installers, owners, users, and governing bodies of steel mesh containment panels used in pallet rack and vertical storage system applications and to achieve the following objectives:to provide guidelines for the design and testing of steel mesh containment panels used in pallet rack and vertical storage system applications;to promote the understanding of the respective responsibilities of manufacturers, sellers, installers, owners, users, and governing bodies associated with steel mesh containment panels used in pallet rack and vertical storage system applications; andto provide a uniform means of testing steel mesh containment panels used in pallet rack and vertical storage system applications.This standard provides performance and testing requirements for vertically-mounted steel mesh containment panels used in pallet rack and vertical storage system applications to contain and minimize the potential for falling items, protecting personnel, product, and property. 

Often referred to as a wire mesh container, this material handling device is made from welded metal wire mesh and possesses a substructure to give the container strength and rigidity. A container that is made of woven, knit or knotted material of open texture with evenly spaced holes.

A receptacle (such as a box, enclosure) or a formed or flexible covering for the packing or shipment of articles, goods, or commodities. Containers may be constructed of plastic, welded wire, corrugated steel or aluminum. To obtain more information on the features and benefits on materials used to construct containers, please click below: Industrial Metal Containers and Wire Decking (IMC&WD) Reusable Container & Pallet Association (RCPA)

A container that can stack within another container when empty. See also Nesting container .

This document contains detailed examples on how storage rack designers can apply the formulas and guidance found in ANSI MH16.1-2023 in their designs and calculation packages.

When you’re manufacturing product for a customer, the final step in the packaging process usually to place containers of products onto a pallet for shipping – either to a distribution center or directly to your customer – so it’s a pretty important step. However, manual palletization (employees physically putting containers on pallets) is often considered one of the least desirable activities; the containers are heavy to lift and in many cases the position on the pallet requires extended reaching. It can be a back breaking job and it may even be causing employee safety concerns for the company. But there is another option. Robotic palletizing exists, and it can be a solution for your company.

The 2014 National Electrical Code has a number of paragraphs affecting electric chain and wire rope hoists. Some of these paragraphs are subject to varying interpretations. Therefore, acting through the electrical engineering subcommittee of the HMI engineering committee and with the approval of the HMI Board of Directors, the Hoist Manufacturers Institute has developed and authorized the publication of the consensus contained within this pamphlet. It is hoped that this HMI Consensus will be mutually helpful to users, manufacturers and sellers of electric chain and wire rope hoists. For specific commentary with respect to individual brand hoists, users and sellers should contact the manufacturer(s) of their electric chain and wire rope hoist(s).