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How DELIECN Built a 13,790-Location Heavy-Duty ASRS for Battery Aluminum Foil Storage
As battery aluminum foil production increases, warehouse capacity often becomes a major bottleneck. Heavy finished goods, iron frames, wooden boxes, and packaging materials occupy large floor areas. If the warehouse continues to rely on floor stacking, storage soon becomes scattered, difficult to manage, and unsafe.
In one battery aluminum foil project, the customer’s existing warehouse could store about 2,500 units. Other materials had to be placed in temporary storage areas around the plant. This affected traffic routes, shipping areas, inventory management, and site order.
DELIECN helped the customer plan and implement a heavy-duty ASRS with 13,790 pallet locations.
Original Storage Condition
The customer’s existing warehouse was approximately 70 m × 40 m with a height of 12 m. Materials were mainly stored by floor stacking.
Finished goods and physical materials were stacked up to three layers, while packaging materials such as empty wooden boxes and empty iron frames were stacked up to four layers. This method created several problems:
- limited warehouse capacity
- scattered storage locations
- difficult goods searching
- high forklift operation intensity
- paper-based record errors
- low traceability
- higher stacking safety risks
Capacity Requirement
DELIECN first conducted demand research based on production efficiency, inventory cycle, and future business growth.
The project required approximately 650 boxes per day. Based on a 12-day average inventory cycle and a 1.5 growth factor for future development, the calculated storage demand reached about 11,700 units.
This showed that the existing floor-stacking mode could not support long-term production growth.
Why the Existing Warehouse Was Not Enough
In the first design stage, DELIECN evaluated the possibility of using the existing warehouse. However, after considering the building height, usable space, and maintenance access, the existing warehouse could only provide about 4,000 storage locations.
This was still far below the required 11,700 units.
As a result, the customer decided to build a new high-bay automated warehouse close to the production workshop.
Final ASRS Design
The final heavy-duty ASRS provided 13,790 pallet locations. The warehouse used a 31.6 m high-bay racking system and 19 storage levels.
To match different material weights, the rack load capacity was designed by level:
Levels 1–10
2,500 kg per location
Levels 11–14
1,500 kg per location
Levels 15–19
500 kg per location
This “heavy goods in lower levels, light goods in higher levels” design helped reduce structural pressure while meeting real storage needs.
Project Value
The project also reduced forklift dependency by approximately 30%–50%, helping the customer move from manual, scattered storage to centralized digital Warehouse Management.
Why This Capacity Planning Works
The success of this project came from capacity planning based on real production data rather than simple warehouse area calculation. DELIECN considered:
- daily production volume
- average inventory cycle
- future growth
- material size and weight
- old warehouse constraints
- new building height
- rack level load distribution
- inbound/outbound flow
- WMS/WCS management logic
Need to evaluate whether your existing warehouse can support future production growth?
DELIECN can help plan heavy-duty ASRS capacity based on real production, inventory, and material data.