Automated Storage & Retrieval Systems (ASRS)

About Us:

Greenvac provides smart technologies and design engineering that increases a facility’s efficiency and improves cleanliness and aesthetics. It brings a powerful continuum of solutions, technology, innovation and execution.

Greenvac (along with its technology partners) works with facility owners, Developers, Architects, Consultants, Governments or stake holders to create a SMART, Green, Healthy & Clean environment through efficient systems.

An experience of many years in automation in various extensive and diverse backgrounds, Greenvac and its technology partners have perfected the development, installation and maintenance of state-of-the-art solutions.

Greenvac, is a unit of UNG which has been catering to many sectors since 1953.

How It Work:

Greenvac Automated Storage and Retrieval System (ASRS): An Automated Storage & Retrieval System (ASRS) consists of Computer Controlled & PLC based stacker crane driven system for automatically placing & retrieving materials from defined storage locations.

The ASRS can be used in situations involving small or high volumes of goods storage. It allows more storage space due to high-density storage & narrower aisles. It exploits the vertical height of space provided. An ASRS based storage automation solution increases efficiency of Material Tracking, handling and overall throughput. Inventory is maintained on FIFO or on call basis and is managed through our advanced Inventory Management System, which also interfaces with the electro mechanical components.

Vertical Carousel – G Cabinet

Constructional Features:

The most modern and cost-efficient Storage and Retrieval system for today’s industry.
Use of the complete available height for storage.
Works on a simple Paternoster principle.
Works on a two vertical chain loop mechanism which is electrically driven.
A metal cladding ensures protection this assembly.
A window is provided at ergonomic level or multiple levels for easy loading and unloading of material.
Entire control using a PC based software with versions for inventory and document management, a PLC controller and an emergency manual mode.
Customised height of the system .
Modular construction.
Customized designed trays to suit shape, dimensions and weight of the material to be stored.
Low noise due to well-engineered guiding mechanism using high quality bearings.
Fast retrieval due to higher speed and shortest path logic built in.
Low power consumption due to energy efficient motor and other components.
More compact design compared to other equivalent systems to save floor space.
Ease of interface of the bundled software with existing systems, ERP, Warehouse Management Systems or similar.
Controller:

Advanced PLC controller with HMI for numeric display.
Quick material retrieval using the shelf number or even the part number.
The system rotates in clockwise or anticlockwise direction to select the shortest possible path.
Can be interfaced with computer.
Advantages:

Smooth Operation: The system ensures jerk-free movement even at start-stop operations due to VFD (Variable Frequency Drive), avoiding damage to the stored material. Special technology for smooth engagement/ disengagement of moving parts ensures low noise level.
Safe and Secure: The curtain sensors at the material retrieval window stop the system in case the material is protruding outside the tray or if an operator tries to access the shelf while it is running. Locking provision for the entire system and emergency stop switch provide further safety.
Low Power Consumption: The system operates on single phase or three phase supply. Specially developed energy-efficient power management of Greenvac systems ensures further power saving.
Quick retrieval of material: The automated system increases number of pick-ups per shift, effectively reducing manpower engagement. Typically, this system is nearly 80% more efficient than conventional storage.
Optimum Space Utilisation: Effective use of optimum height results in floor space saving up to 90%.
Manpower Saving: Less manpower engagement compared to conventional stores.
User-Friendly: Even an unskilled person with a little training can very effectively use the G Cabinet. In case of power failure, it can be operated manually. Routine maintenance requires only oiling and greasing, which can be carried out easily by quickly removing the side covers.
Power Backup: In built UPS provision for operating the system in case of power failure may also be given.
Quick Installation: No special provisions are required on site such as pits/foundation and hence, this modular system can also be installed quickly on site.
Operations @ a Click: The bundled software ensures all parts, documents can be retrieved at the click of a mouse from anywhere. Easy interfacing functionality of our software with existing systems makes the systems really integrated.
Center Retrieval – G Store

Ideal for mid-sized, mid-weight and heavy weight components varying in shape, size and weight.
System offers higher flexibility to accommodate a variety of items to be stored.
The pitch between two trays can be variable, allowing storage of items with variable dimensions.
In this system, trays are stationary while the retrieving mechanism is moving, which increases load capacity per shelf (up to 1MT per tray or as required).
The PLC-controlled platform known as retriever is similar to a lift, moves up and down to locate a particular tray while storing/retrieving the material. The desired tray is brought to the operating window located at ergonomic level for easy loading or unloading of material.
Very easy to operate and maintain and allows full utilisation of the available height.
Height sensor at each window(s).
Constructional Features:

The system is completely enclosed using metal cladding and has one ore multiple operating window(s) at ergonomic level.
The operating window is lockable using electro- mechanical mechanism. Additional sensors provide higher safety to the operator as well as operating system.
The system is constructed using precision fabricated pipes, channels and metal and can be customised to suit the customer’s requirements.
Retrieving mechanism or platform is fitted to vertical chain loops at four corners of the platform which give upward and downward motion to the platform with back and forth movement.
Advantages:

Quick Retrieval: The system is faster as compared to G Cabinet. In this system, only the retriever is moving and not all the trays, ensuring faster retrieval.
Space Saving: Utilizes complete height and saves horizontal space up to 80%.
Optimum Storage Capacity: This system allows larger tray dimensions compared to vertical carousel and also varying pitch is possible, allowing storage of material of different shapes and sizes in the same system.
Higher Load Capacity: Shelves are stationary and can be designed for 1MT load capacity (per shelf).
Safety of Material: Totally enclosed system, avoids damage to material from external influences and protects material from theft.
Manpower Saving: High degree of automation reduces manpower requirement.
Effective Inventory Control: Material can be accessed only after entering the part number and quantity, in turn ensuring timely update of record. This allows precise inventory control.
User-Friendly System: Very easy to operate and maintain after a brief training.
Smooth Operation: Only the retriever is moving up and down with the help of a chain and sprocket mechanism, thus ensuring very low noise and jerk- free material handling.
Operator Safety: Curtain sensors at the opening window ensure the operator safety during operation and prevent accidents. Emergency switch at front allows instantaneous halting during operation in case of an emergency.
Advanced Inventory / Warehouse Management System for Storage System

Gives the user full control of the storage and retrieval process for material inventory through a single and simple browser based interface.
Provision for tracking inventory from suppliers, for clients as well from production line.
Track raw material, in process and finished product inventory and storage.
Generation of documents related to inward, movement and dispatch of inventory.
Intelligence built in to guide the user to the correct available location for storage, based on product dimensions and available space.
Triggers for various parameters such as dispatch date, expiry date and several others.
Available API’s, being open source and open architecture based system, to ensure ease of integration with various protocols and third party systems and Databases.
Facility to integrate with a bar code based or RFID based tagging application and other existing client applications.
Uses web technologies, can be accessed over a network or the internet through any device.
Full inventory report.
Category-wise and code wise or material name wise real time inventory view.
Customer wise, vendor wise and user wise inventory reports.
Complete transaction log report of inventory storage and retrieval along with user details and time stamp.
Location wise inventory report.
Date wise check-in, check-out view of inventory.
Report on shelf life or expiry of materials.
Cost of inventory report.
Re-order level wise inventory report.
Planned dispatch report.
Customer/consumer wise report mapping materials to destinations and date of delivery or dispatch.
All reports will be in listing as well as dashboard/graphical formats wherever required with further drill down facility.