Stacker cranes: existing types and when to choose them - LCS Group

Stacker cranes are a great asset in the world of logistics because they help automate the operating cycle. They are the backbone of automated warehouses, thanks to which many companies are able to improve performance, speed up the handling of goods and increase their productivity.

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Stacker cranes are machines used to automatically store and pick various types of goods such as pallets, boxes, containers, tyres. They are robots and, thanks to control systems integrated into them and warehouse management software, stacker cranes are able to execute all commands given to them.

These machines are programmed to store products automatically at the pre-determined location, guaranteeing error-proof and low-cost work. Stacker crane operated warehouses can be over 150 metres long and up to a maximum of 45 metres high.

What does a stacker crane consist of and how does it move?

• By a mobile frame that moves by means of belts, chains or supporting ropes, along a vertical structure and within an aisle, typically bounded by two racks;
• The vertical structure actually consists of one or more columns in turn anchored to a beam running along a rail on two supporting wheels, one driving and one driven. In some cases, machines with several driving wheels are designed for high-performance machines;
• There are contrast wheels at the top that keep the sideshifter upright.

Depending on the goods to be handled, there are different types of stacker cranes: stacker cranes for pallets or for larger and heavier goods, and miniloads, for handling lighter and smaller loads.

In addition, they can handle single- or double-deep and multiple-deep warehouses, i.e. with a variable number of containers per side.

Stacker cranes for pallet

Stacker cranes for pallet are designed for the automatic storage and pick of pallets, boxes and other bulky loads. They move along aisles according to the commands of specific software that allows an operator to manage them.

The dimensions of the pallet stacker cranes can reach a height of 45 metres in their self-supporting warehouse version, with load capacities of over 10 tonnes.

The strengths of automatic stacker cranes include:

• the precise automation of pallet entry and exit,
• improving the management of inventories by constantly updating them,
• the elimination of errors typical of manual operations,
• the speed of picking, regardless of unit size,
• the guarantee for operators to work in complete safety,
• the possibility of being equipped with mechanisms for recovering energy during braking
• their energy efficiency,
• the versatility, which allows them to adapt to almost all types of goods and different temperatures, even as low as -35 °C in a cold store.

There are two main types of pallet stacker cranes: single-column and double-column.

Single-column stacker cranes

Single-column pallet stacker cranes, as the name suggests, consist of a single column and are most suitable for warehouses with lighter loads. In this sense, we can indicate an ideal pallet weight of between 1,000 and 1,500 kg.

Double-column stacker cranes

In this type of stacker crane, the structure with two vertical columns corresponds to an elevation cradle in the centre, which allows access to all storage levels. As double-column stacker cranes are stronger than single-mast cranes, they are well suited to handling heavy or bulky loads.

Miniloads

The miniload is a machine similar to the stacker crane but with a tendentially lighter structure, designed to handle boxes or plastic crates. The advantages to be found in this type of stacker crane are the same as those already mentioned in those for pallets, simply related to smaller loads and dimensions.

As far as their configuration is concerned, the miniload stacker cranes also come in single-column and double-column variants. The twin-column stacker cranes for containers can be up to 20 metres high, moving up to four containers weighing over 50 kg each at the same time.

LCS Group’s automated storage solutions

LCS Group, operating since in the fields of internal logistics and industrial automation, designs and manufactures automatic warehouses that can also be customised on request. Since the stacker cranes represent the focal point of the system that makes up the automatic warehouse, it is important to be able to count on a wide choice of products that vary according to the load capacity, the size of the goods and the type of height to be reached for storage.

Efficient warehouse operations are critical in today’s fast-paced logistics environment. As supply chains grow more complex, businesses need advanced solutions to meet the demand for faster, more accurate storage and retrieval of goods. One such solution that has proven invaluable in modern warehousing is the stacker crane. In this article, we will dive deep into the world of stacker cranes, examining the different types, their benefits, how to choose the right one for your needs, and the role they play in optimizing warehouse performance.

What is a Stacker Crane?

A stacker crane is a mechanized system designed to handle goods in a warehouse setting, specifically for automated storage and retrieval systems (AS/RS). It moves along fixed tracks and is equipped with a lifting mechanism to retrieve or store items at various levels within a racking system. Stacker cranes are typically used in high-density storage environments where maximizing space efficiency is a priority.

Why Stacker Cranes Are Essential for Modern Warehousing

In today’s logistics landscape, businesses are under increasing pressure to improve operational efficiency, reduce costs, and handle higher volumes of goods. Stacker cranes offer several key advantages that make them an indispensable part of automated warehouse solutions:

1. Space Optimization: They enable vertical storage, making full use of the available warehouse height.
2. Speed and Accuracy: Stacker cranes offer fast, automated retrieval and placement of goods, minimizing errors.
3. Cost Efficiency: By reducing the need for manual labor and improving throughput, stacker cranes contribute to significant cost savings.

Types of Stacker Cranes

There are various types of stacker cranes designed to meet different warehousing needs. Each type has its unique advantages depending on the size of the warehouse, the type of goods being stored, and the desired throughput speed.

Single-Mast Stacker Cranes

Single-mast stacker cranes are lightweight and versatile. They have one mast and are designed for handling lighter loads. Their compact structure allows for faster movement and is ideal for small to medium-sized warehouses that don’t require heavy-duty lifting.

Double-Mast Stacker Cranes

Double-mast stacker cranes are built for strength and stability. With two masts, they can handle heavier loads and are commonly used in large warehouses with higher throughput requirements. Double-mast cranes are often found in facilities storing bulky or oversized items.

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Miniload Stacker Cranes

Miniload stacker cranes are designed for smaller goods, such as boxes or bins. These are commonly used in e-commerce or retail distribution centers where items need to be picked quickly and accurately. Miniload systems are ideal for handling small, lightweight products at high speeds.

Unit Load Stacker Cranes

Unit load stacker cranes are designed to handle full pallets or larger loads. These are typically used in industries like manufacturing and automotive, where large or heavy items need to be moved and stored efficiently. They can manage both lightweight and heavyweight goods, depending on the crane’s capacity.

Key Components of a Stacker Crane System

To better understand how a stacker crane operates, let’s break down its essential components:

Mast

The mast is the vertical structure along which the crane moves up and down to store or retrieve goods at different levels. The mast’s strength and height are key factors in determining the load capacity and reach of the stacker crane.

Lifting Mechanism

The lifting mechanism raises and lowers the platform or fork that carries the goods. Depending on the type of stacker crane, this mechanism can be designed for high-speed operations or heavy-duty lifting.

Rail System

Stacker cranes operate on a rail system that guides the crane horizontally across the warehouse. The rail system ensures precise movement and enables the crane to access different aisles or storage zones.

Load Handling Device

The load handling device is the part of the crane that interacts with the goods, such as forks, platforms, or clamps. This component plays a critical role in ensuring the safe and efficient handling of different types of loads.

How to Choose the Right Stacker Crane for Your Warehouse

Selecting the right stacker crane for your warehouse depends on various factors, including the type of goods you store, your warehouse layout, and your specific operational needs.

1. Load Size and Weight

The weight and size of the loads your warehouse handles are crucial considerations. If your operation involves heavy pallets, a double-mast or unit load crane would be more appropriate. For smaller items, a miniload crane may be the best fit.

2. Warehouse Height

Maximizing vertical space is a key benefit of using stacker cranes. The height of your warehouse will determine the type of mast you need. High-bay warehouses, for example, require cranes with extended reach to access goods stored at the highest levels.

3. Throughput Speed

The speed at which goods need to be stored and retrieved is another important factor. If your warehouse operates at a fast pace with high turnover, you’ll need a stacker crane that prioritizes speed and efficiency, such as a single-mast or miniload crane.

4. Aisle Width

Warehouse aisle width will dictate the size and maneuverability of the crane. Narrow aisle stacker cranes are designed for environments with limited space between racks, while wider aisle cranes can accommodate larger, more open spaces.

The Role of Stacker Cranes in Automated Storage and Retrieval Systems

Automated storage and retrieval systems (AS/RS) rely heavily on stacker cranes to handle the storage and retrieval of goods. These systems are integrated with warehouse management software (WMS) to streamline operations and provide real-time inventory tracking.

Benefits of AS/RS with Stacker Cranes

1. Reduced Labor Costs: Automation significantly cuts down on the need for manual labor, reducing the potential for human error and operational costs.
2. Increased Inventory Accuracy: With AS/RS, every movement of goods is tracked and recorded, ensuring accurate inventory data at all times.
3. Improved Safety: By automating the handling of heavy or hazardous goods, AS/RS reduces the risk of workplace accidents.

Stacker Crane vs. Traditional Forklifts: Which is Better?

Forklifts have long been a staple of warehouse operations, but how do they compare to stacker cranes in today’s automated environments?

Efficiency

While forklifts are versatile, stacker cranes provide higher efficiency, especially in high-density storage environments. Cranes can retrieve items faster and more accurately than forklifts, which are limited by human operators.

Space Utilization

Stacker cranes allow for better space utilization by enabling vertical storage. Forklifts, on the other hand, require wider aisles and can’t reach the same heights as cranes, leading to less efficient use of available space.

Innovations in Stacker Crane Technology

As technology evolves, stacker cranes continue to improve in both functionality and efficiency.

Smart Control Systems

Modern stacker cranes are equipped with smart control systems that optimize movement, reduce energy consumption, and enable predictive maintenance. These systems are integrated with warehouse management software to provide real-time data on performance and maintenance needs.

Energy Efficiency

Many stacker cranes now feature energy recovery systems that capture and reuse energy generated during braking or lowering movements. This leads to significant energy savings and a more sustainable operation.

Conclusion

Stacker cranes are revolutionizing the way warehouses operate by offering unparalleled efficiency, space utilization, and cost savings. As logistics demands grow, adopting automated solutions like stacker cranes is becoming essential for businesses looking to stay competitive in the fast-moving world of supply chain management. When selecting a stacker crane, consider factors such as load size, warehouse height, and throughput speed to ensure you choose the best system for your needs.

Investing in the right stacker crane system will not only enhance your warehouse’s operational efficiency but also future-proof your business against the growing complexities of modern logistics.

Post time: Oct-21-