Maximizing floor space and efficiency with automated vertical storage

When a major foodservice equipment manufacturer set out to improve their storage and picking processes, they turned to Prestige for a smarter, space-saving solution. With over 28 feet of vertical clearance available, their facility was an ideal candidate for automation—and Modula VLMs offered the performance, efficiency, and flexibility they needed.

Watch the transformation unfold in this timelapse video:

The Challenge: Inefficient Use of Space Across Two Key Areas in the Warehouse

The project focused on two key zones within the facility:

1. Sheet Metal Storage Area
2. Warehouse Order Picking Area

Both areas were filled with traditional pallet racking, shelving, and mezzanine-supported structures that consumed valuable floor space. Storage utilization in some zones was as low as 20%, while others were densely packed but inefficiently organized. The fragmented workflows—especially in the multi-level pick module—created slowdowns and inconsistencies in order fulfillment.

Sheet Metal Storage: Compacting the Heavyweights

The sheet metal area previously consisted of ten sections of low-profile pallet rack, used to store loose parts and totes. While this approach provided a basic level of organization, it left much of the rack depth unutilized. In total, the footprint occupied 849 ft², but there was only 756 ft² of shelf area storage when aggregating all pallet racking levels.

Prestige designed and installed a Modula ME75 vertical lift module tailored to handle dense sheet metal parts. This single unit reduced the storage footprint to just 67 ft², freeing up more than 750 ft² for other uses in the facility.

Key features of the solution included:

• 1,653 lb tray capacity, optimized for heavy steel components
• External bay access for safe and ergonomic handling of bulky items
• 80 trays with 4.72-inch walls, suitable for stacking low-profile parts
• Potential to expand up to 91 trays for future growth

This not only consolidated the material into a much smaller footprint, but also significantly improved accessibility and safety for warehouse staff.

Bolted Guard Rail

$53.50 – $187.00Price range: $53.50 through $187.00

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Teardrop Upright Frame

$126.00 – $380.00Price range: $126.00 through $380.00

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Roll-Form Teardrop Step Beam

$14.50 – $102.00Price range: $14.50 through $102.00

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Wire Decking Panel

$18.00 – $47.50Price range: $18.00 through $47.50

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Guard Rail Post

$118.00 – $163.00Price range: $118.00 through $163.00

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Lift Out Pocket Set

$104.50

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Row Spacer

$13.50 – $16.50Price range: $13.50 through $16.50

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Post Protector

$97.00 – $104.00Price range: $97.00 through $104.00

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End-of-Aisle Guard

$343.00

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Pallet Support

$8.50 – $18.00Price range: $8.50 through $18.00

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Warehouse Pick Module: High-Volume Efficiency

The second focus area was the warehouse order picking zone. This area used a mix of pallet racking, shelving, and a rack-supported mezzanine. It occupied over 4,500 ft² and presented a number of inefficiencies—particularly related to travel time, pick accuracy, and the challenges of managing a multi-level system.

Prestige replaced this outdated setup with two Modula ML50D VLMs. Each unit occupies approximately 154 ft², bringing the total footprint to just over 300 ft² while retaining the same storage capacity.

To address the customer’s high order volume, these units were equipped with:

• Dual tray delivery to reduce downtime between picks
• Advanced Picking Software and Put-to-Light functionality for streamlined batch picking
• LED display bars for intuitive part location
• 1,102 lb tray capacity, with a variety of tray partition options for different SKU sizes

These enhancements made it easier and faster for warehouse staff to fulfill orders with fewer errors, reduced fatigue, and better inventory visibility.

End-to-End Project Delivery

Prestige helped this facility reclaim thousands of square feet, streamline operations, and set the foundation for scalable, long-term efficiency. Below is a snapshot of the transformation:

Looking Ahead

By replacing outdated racking with vertical automation, the customer reclaimed more than 4,900 ft² of usable space. They also achieved faster picking, improved accuracy, and safer handling of both heavy and high-volume items.

Prestige is proud to support companies across the Southeast in building smarter, more scalable warehouse operations.

Interested in exploring what Modula VLMs could do for your facility? Contact Prestige today to schedule a consultation.

Frequently Asked Questions About Modula VLMs