PICK MODULE SYSTEMS
Pick modules are an important addition to your warehouse or distribution center, as it greatly increases your picking rate, and thus boosts your facility’s throughput and efficiency levels.
A pick module is typically used for full case or broken case picking of orders. It usually has a ground-level structure , with one to two2 elevated mezzanine levels that are accessed via stairs. Items are picked from full pallets or carton flow lanes into totes. Full pallets may be on a static rack, or stored in 2-deep or 3-deep pallet flow lanes. Additionally, a conveyor system may be part of the pick module to transport partial or completed orders to other levels for additional items to be added or shipping preparation.
The support structure can be comprised of pallet racking, shelving or structural mezzanine components. The flooring can be solid or open, however solid is heavily favoured since small items cannot fall through and personnel may be uncomfortable looking through an open floor system. Whether the floor is open or closed, a sprinkler system is required on all levels along with lighting, emergency lighting and exit signage.
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Most municipalities require a building permit to be issued for multi-level pick modules. The building permit submission usually needs to detail the structural design, post-loading, egress routes, sprinkler system and lighting system design elements.
As a turn-key service provider, we assist in building permit acquisition, facility layout design, and all other storage system services required to get the job complete.
- Concept Storage Solutions Ltd is well versed in the design, manufacture, installation and implementation of a wide variety of pick module configurations.
PICK MODULES SYSTEMS USED
PICK MODULES FAQs
A pick module is a multi-level, engineered storage system designed to move high volumes of product through a distribution center. It essentially “stacks” racking and storage mediums (like pallet flow, carton flow, and shelving) vertically, connected by mezzanines, stairs, and conveyors. This allows you to consolidate a massive amount of SKUs into a small footprint and facilitates a highly efficient pick path.
By using a strategy called “dense picking.” Instead of an operator walking miles across a warehouse floor, the fast-moving inventory is concentrated in the pick module.
- Gravity Flow: Carton flow racks gravity-feed products to the pick face, so stock is always available.
- Conveyor Integration: Once an order is picked, it is typically placed on a center take-away conveyor that whisks it away to shipping, eliminating the need for the operator to walk the order to a pack station.
Absolutely. Modern pick modules are often hybrid systems. You can integrate Pick-to-Light or Voice-Picking systems to guide operators. Furthermore, you can install Vertical Reciprocating Conveyors (VRCs) or spirals to move heavy pallets or restock items between the different levels of the module automatically.
Safety is the primary engineering constraint. Pick modules are built with rigorous safety standards, including kick plates, guard rails, safety gates for pallet drop zones, and netting to prevent items from falling. They must meet strict OSHA and IBC (International Building Code) seismic and fire suppression standards (like in-rack sprinklers).
They are entirely custom-engineered. A pick module is not an “off-the-shelf” product. The design depends on your SKU velocity (how fast items sell), the size of your boxes, and your building’s column spacing. A system can be designed with two levels or four, with pallet flow on the bottom level for bulk items and shelving on top levels for slow movers.
