The UltraStore Mini Load ASRS stores and retrieves totes and bins with proven mini-load ASRS storage density and throughput. No embedded track. No single point of failure. No proprietary parts. You get reliable performance, simplified maintenance, reduced capital investment, and rapid ROI.
This system delivers the storage density you need without the complexity that drives up ownership costs. Your operations team gets consistent throughput. Your maintenance team gets easy access to standard components. Your CFO gets faster payback.
ISD designed the UltraStore Mini Load ASRS from 60 years of ASRS experience and decades of manufacturing and implementing hundreds of UltraStore Mid-Load ASRS systems. We eliminated the pain points that plague traditional ASRS and mini-load systems. The result: automated tote and bin storage that fits your budget and keeps running.
The UltraStore Mini ASRS is an automated storage and retrieval system engineered for high-density tote and bin handling. It shares the proven architecture of ISD’s flagship UltraStore Mid-Load system but optimizes for smaller load units.
The system stores totes and bins in vertical racking structures. Inserter/extractor bots retrieve items on demand and deliver them to picking stations, conveyors, or AMRs. Your team picks orders. The system returns containers to storage. The cycle repeats hundreds and thousands of times per shift.
You use the UltraStore Mini ASRS to consolidate inventory into a smaller footprint. You eliminate wasted floor space. You reduce operator walking and searching time. You increase picking accuracy. You scale capacity vertically instead of horizontally.
The system integrates with your warehouse management systems (ERP, MES, WMS, WES) through standard protocols to ISD’s Advanced WCS software. Your MES/WMS sends pick requests. The UltraStore Mini retrieves the right bins. Your operators’ complete picks. Inventory updates automatically. No manual intervention required.
Implementation starts with analysis of your storage and throughput requirements. ISD’s OptimalOps-Process identifies the right system configuration for today, tomorrow and future. We design the layout. We install the system. We train your team. We provide 24-7-365 service. You start running production.

The UltraStore Mini ASRS adapts to diverse storage and retrieval applications. Distribution centers use it for small parts picking. Manufacturers use it for component storage. E-commerce operations use it for order fulfillment.
The UltraStore Mini ASRS comprises several integrated subsystems. Each component contributes to reliable operation and easy maintenance.
Storage Structure: The vertical racking system uses standard warehouse rack components. No precision or custom steel fabrication required. Rack heights adapt to your building constraints.
Inserter/Extractor: Automated shuttles move horizontally and vertically to access storage locations. The system uses commercial motion control components.
Tote Handling: Standard totes and bins fit the system. You’re not locked into proprietary containers. The system handles multiple tote sizes in the same structure. This flexibility supports diverse product ranges.
Control System: Industrial PLC architecture provides reliable control. The system uses proven automation platforms. System diagnostics identify issues before they cause downtime.
Software Integration: Open architecture integrates the Advanced UltraStore Mini WCS software to any warehouse management system. Standard protocols eliminate custom interfaces. Real-time status reporting keeps your WMS synchronized. You maintain inventory accuracy.
Safety Systems: Multiple safety zones protect operators. Light curtains prevent unauthorized access. Emergency stop controls position strategically. The system meets ANSI safety standards.
Power Distribution: Energy-efficient drives reduce operating costs. Standby mode minimizes power consumption during idle periods. You reduce utility expenses.
Pick Workstations: Pick stations integrate with multiple technologies such as pick-to-light, weigh scales, RF scanning, printers, auto baggers, dunnage systems, box erectors, shipping software and virtually any other technology required. Ergonomic design reduces operator fatigue. One or more workstations support your throughput requirements.
The UltraStore Mini ASRS transforms your storage and picking operations. You gain control over costs, space, and accuracy.
Multiple industries deploy the UltraStore Mini ASRS to solve specific operational challenges. Each industry values different system capabilities.
Successful implementation requires careful planning. ISD’s OptimalOps-Process guides you through critical decisions.
Throughput Requirements: Calculate your peak hourly retrieval needs. The system scales to match your volume. Underestimating throughput creates bottlenecks. Overbuilding wastes capital. ISD’s analysis ensures right-sizing.
SKU Profile: Document your product dimensions and storage requirements. Container standardization simplifies system design. Mixed SKU profiles need careful planning. We optimize tote sizing for your products.
Building Constraints: Measure ceiling heights accurately. Structural capacity matters for vertical storage. Floor levelness affects installation costs. We design around your facility limitations.
Integration Requirements: Your WMS capabilities determine integration complexity. Legacy systems may need middleware. API documentation speeds implementation. We work with all major WMS platforms.
Growth Planning: Consider three-year volume projections. Modular design allows expansion. Plan for future capacity now. You avoid costly retrofits later.
Operational Workflow: Map current processes before automating. Identify improvement opportunities. Plan for change management. Your team needs proper training.
Maintenance Capabilities: Assess your team’s technical skills. Basic troubleshooting happens in-house. Complex repairs may need support contracts. We provide comprehensive training.
Budget and ROI: Calculate total cost of ownership. Include installation, training, and ongoing costs. Document labor savings and productivity gains. Most projects pay back in 18-36 months.
The UltraStore Mini ASRS accepts distinct options to match your operational requirements. You configure the system for your specific needs.
The UltraStore Mini ASRS scales to your requirements. Standard configurations accommodate most applications. Custom designs address unique needs.
Specification | Metric | Imperial |
Tote Capacity | 500-5,000+ positions | 500-5,000+ positions |
System Height | 6-15 meters | 20-50 feet |
Tote Load Capacity | Up to 25 kg | Up to 55 lbs. |
Throughput | 100-400+ totes/hour | 100-400+ totes/hour |
Tote Dimensions | 400-600mm L x 300-400mm W | 16-24 in L x 12-16 in W |
Power Requirements | 480V 3-phase | 480V 3-phase |
Picking Accuracy | 99.9%+ | 99.9%+ |
Typical Footprint | 50-500 m² | 500-5,000 sq ft |
*All specifications are nominal and subject to change without notice.
ISD welcomes custom configurations to accommodate specialized requirements. Contact us to discuss your specific application.
ISD brings over 60 years of material handling experience to your project. We’ve designed and installed decades of automated systems. Our track record speaks for itself.
Our OptimalOps-Process ensures right-sizing. We analyze your actual requirements. We don’t oversell capacity you don’t need. We design systems that match your budget and performance goals.
We’re OEM agnostic. We will pick the best components for your application. We’re not tied to single suppliers. You get proven technology at competitive prices.
We manufacture the UltraStore product line. We understand the equipment intimately. Our engineers designed it. Our technicians maintain it. You get factory-direct support.
We provide complete lifecycle support. Initial consultation leads to design, installation, training, and ongoing maintenance. One company handles everything. You avoid coordination headaches.
Our team includes former warehouse managers and operations directors. We understand your challenges. We’ve walked your floors. We design solutions that work in real operations.
We maintain inventory of critical spare parts. Your downtime gets minimized. Emergency support responds quickly. We keep your system running.
The ISD service network provides North American coverage. Our technicians travel to your site. Remote support handles many issues. You get help when you need it.
Most installations pay back in 18-36 months. Labor savings provide the primary ROI. Space recovery and accuracy improvements contribute additional value. Your specific payback depends on current labor costs and throughput volumes.
Typical installations are completed 8-12 weeks from equipment arrival. No embedded track means faster floor preparation. Your facility operates during the installation. System commissioning takes 1-2 weeks.
Preventive maintenance schedules quarterly. Your team handles basic tasks like lubrication. Annual inspections check critical components. Most parts last years before replacement. We provide detailed maintenance documentation.
Yes.Modular design allows capacity additions. You add storage aisles, existing aisle length or additional inserter and extractor bots. Existing system keeps running during expansion. Software updates handle new capacity automatically.
Redundant design maintains operation. Other mechanisms handle workload. System performance may be reduced temporarily. You schedule repair during off-hours. Critical spare parts ship overnight.
Standard protocols integrate to virtually every MES/WMS platform. API documentation simplifies integration. Real-time status updates keep systems synchronized. Existing warehouse processes adapt easily.
Basic operation training takes 2-4 hours. Operators learn picking procedures. System alerts guide them through exceptions. Most workers become proficient in hours.
Probably. The system accommodates standard warehouse totes. We verify compatibility during design. Custom tote sizes work with some modifications. Standardizing containers simplifies implementation.
Picking accuracy exceeds 99.9%. Automated retrieval eliminates location errors. Verification systems catch remaining mistakes. Your shipping accuracy improves dramatically.
Know your busiest hour volumes. Document seasonal peaks. Understand future growth projections. This determines proper system sizing.
Calculate total facility costs. Include rent, utilities, and property taxes. Divided by usable square footage. This quantifies space recovery value.
Track current labor allocation. Include direct and indirect time. Calculate fully-loaded labor costs. This establishes baseline for ROI calculations.
Measure actual order accuracy. Document error types and frequencies. Calculate costs from returns and replacements. This shows accuracy improvement in value.
Measure actual clear height. Account for sprinklers and lighting. Check structural loading capacity. Height determines vertical storage potential.
Plan for parallel operations during cutover. Identify training needs for your team. Schedule implementation timing carefully. Change management determines success.
Assess electrical and mechanical skills. Determine training requirements. Plan for support contracts. This affects long-term operating costs.
Document container types and sizes. Consider standardization opportunities. Multiple sizes complicate design. Standardizing reduces costs.
Review API documentation. Identify integration resources. Check system limitations. Integration complexity affects timeline and cost. ISD will be with you every step for a seamless integration.
Project volume increases over 3-5 years. Consider new products or customers. Plan expansion capacity now. This ensures scalable design.
Contact Us for More Information About UltraStore Mini-Load ASRS