Automated Storage & Retrieval System by Webb-Stiles
What is an Automated Storage & Retrieval System (ASRS)?
An Automated Storage & Retrieval System (ASRS) is a material handling solution that stores and retrieves large, heavy items with precision and efficiency. Unlike standard conveyor systems that move products continuously, ASRS offers controlled storage and on-demand retrieval. As a result, it is ideal for managing inventory in production environments where space is limited and material flow requires careful control.
At Webb-Stiles, ASRS systems are custom-engineered using transfer cars, heavy-duty storage racks, and gravity-fed steel trays. Materials such as steel bars, rounds, flats, or sand cores are loaded onto trays. From there, the transfer car moves each tray along its path and lifts it into a designated storage position. This design streamlines material access and supports router operations, mold preparation, and casting buffers, ensuring materials are retrieved at the right time.
Webb-Stiles designs each ASRS system to meet the facility’s unique demands, building solutions capable of handling loads from 250 to over 5,000 pounds and material lengths up to 21 feet. Depending on space and capacity needs, Webb-Stiles configures storage racks as single- or double-sided to maximize space efficiency. The team also tailors automation levels to match workflow requirements, delivering the right balance of control and simplicity.
By offering tailored ASRS solutions, Webb-Stiles delivers reliable, space-saving storage and precise retrieval for heavy, hard-to-handle materials. This combination of custom design, proven installation experience, and seamless production integration sets ASRS systems apart from traditional conveyors and other material handling equipment.
Types of Automated Storage & Retrieval Systems
Transfer Car Systems
Every Webb-Stiles ASRS starts with a transfer car that moves steel trays along a dedicated rail path. These cars handle heavy materials like tool steel, bars, flats, and sand cores, with travel distances, lift heights, and speeds tailored to each facility. As a result, the transfer car enables precise positioning for both storage and retrieval, ensuring efficient material flow in demanding environments.
Best for: Heavy-duty storage and retrieval of long, heavy products in production environments where space and controlled movement are critical.
Steel Tray & Gravity Roller Systems
Webb-Stiles designs steel trays to support large, heavy loads and enable smooth loading and unloading through gravity rollers. This configuration minimizes operator effort and eliminates the need for powered roller mechanisms. Consequently, it ensures reliable, low-maintenance operation even in high-load applications where manual or semi-automated handling is preferred. Furthermore, this design provides a simple and effective solution for facilities prioritizing durability and ease of use.
Best for: Efficient handling of heavy, awkward materials where manual or semi-automated loading and unloading is preferred.
Storage Rack Configurations
Storage racks play a key role in every ASRS system. Webb-Stiles custom-builds these racks to fit each project’s capacity and layout, designing them for either single-sided or double-sided storage along the transfer car path. Additionally, each rack holds heavy-duty steel trays that rest on gravity-fed rollers. As a result, operators can easily slide materials into position for storage or retrieval with minimal effort.
Best for: Maximizing vertical storage space in areas with limited floor space, while maintaining easy manual access to heavy materials.
Automation Levels
Webb-Stiles configures ASRS systems as manual, semi-automatic, or fully automated solutions based on the application’s needs. For example, fully automated systems integrate with production equipment and software, providing real-time inventory access. Meanwhile, semi-automatic systems balance automation with manual oversight, offering flexibility for varied production volumes. Furthermore, manual setups deliver the simplest solution, making them ideal for low-volume or basic retrieval tasks.
Best for: Choosing the right balance of automation to match production volume, complexity, and budget.
Applications & Uses
Webb-Stiles ASRS systems provide efficient storage, retrieval, and material flow control for large, heavy products in demanding production environments. By supporting both production and inventory management needs, these systems help optimize workspace, improve access, and maintain balanced operations.
Production & Storage
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Tool steel storage and retrieval
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Handling bars, rounds, flats, and other long materials
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Work-in-progress storage for casting and molding processes
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Buffering materials between production stages
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Feeding cut-off saws, ovens, and machining operations
Inventory Management & Flow Control
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Sand core storage for foundry operations
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Staging materials for router or machining processes
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Space-efficient storage of large, heavy products
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Providing real-time inventory access and tracking
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Balancing material flow for high-mix, low-volume production
Key Features
Webb-Stiles ASRS systems combine heavy-duty material handling with custom-engineered designs to streamline storage, retrieval, and production flow. Each system meets specific operational needs while delivering reliable performance and seamless facility integration.
Heavy-Duty Handling & Custom Design
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Webb-Stiles designs systems to handle loads from 250 to over 5,000 pounds
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Supports material lengths up to 21 feet
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Engineers transfer cars with custom travel lengths and lift heights
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Configures storage racks as single- or double-sided to maximize space
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Builds steel trays for reliable, heavy-duty material support
Operational Flow & Production Integration
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Designs gravity roller trays for smooth, manual or assisted loading/unloading
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Configures systems for manual, semi-automatic, or fully automated operation
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Integrates systems with cut-off saws, ovens, and machining processes
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Supports work-in-progress storage and production buffering
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Provides real-time inventory visibility for efficient material flow
How Automated Storage & Retrieval Systems Are Engineered
Load & Product Handling Comes First
Every ASRS project at Webb-Stiles begins by analyzing the specific product it will store and retrieve. The size, weight, and characteristics of materials—whether tool steel, sand cores, bars, or flats—directly influence load capacity, tray design, and handling methods. Webb-Stiles designs systems to handle loads from 250 to over 5,000 pounds, with steel trays and support structures built for demanding applications.
Tailored to Fit Your Facility & Flow
Facility layout plays a critical role in ASRS design. Webb-Stiles evaluates available space to determine whether storage racks should be placed on one or both sides of the transfer car path. The team then customizes transfer car travel lengths and lift heights to ensure efficient material movement. This approach allows ASRS solutions to integrate smoothly into existing workflows without disrupting operations.
Built for Reliability & Ease of Use
Webb-Stiles prioritizes operational efficiency and minimal maintenance in every ASRS design. Gravity-fed steel trays enable smooth, simple loading and unloading, often manageable by a single operator. By using self-contained transfer car systems, Webb-Stiles eliminates the need for complex conveying infrastructure. Additionally, robust steel construction ensures long-lasting durability and reduces maintenance demands, supporting continuous production flow.
Automation to Match Your Needs
Webb-Stiles offers multiple automation levels to match each facility’s needs. Fully automated systems integrate with production equipment and provide real-time inventory access. Semi-automatic systems balance automation with manual oversight, while manual setups deliver simplicity for lower-volume applications. Throughout the design process, Webb-Stiles collaborates with customers to evaluate critical factors—such as optimal automation level, material access frequency, and opportunities to simplify material flow.
Hanging Methods and Safety Guards
Conveyor hanging methods depend on factors like ceiling height, bay spacing, and structural steel availability. Webb-Stiles designs support structures to fit your facility—not the other way around. Additionally, the engineering team adds custom conveyor guards to protect workers and equipment based on your specific application.
A Collaborative Engineering Process
Throughout every project, Webb-Stiles guides customers through critical design decisions—such as how materials move through the facility, what storage density is required, and how retrieval processes impact production flow. By collaborating closely with each customer, Webb-Stiles develops ASRS solutions that meet technical requirements, solve real operational challenges, and support long-term efficiency.
Downloads & Literature
Access detailed specifications, system configurations, and application guides for Webb-Stiles Automated Storage & Retrieval Systems. These resources showcase real-world solutions designed to optimize material handling and improve production efficiency.
Ready to improve your storage and retrieval process?
Contact our team to discuss a custom-engineered ASRS solution for your facility.