Custom Automated Storage Solutions (ASRS, VLM)

Automated Storage Solutions for Specialized Industrial Applications

Standard storage and load handling options aren’t always the best fit. Sometimes a more innovative approach is needed to accommodate tight tolerances, bulky loads, or additional safety measures. Custom automated storage and retrieval systems (ASRS) and vertical lift modules (VLMs) are designed by Bastian Solutions to meet your unique industry considerations for better performance, reliability, and improved facility operations.

Thorough testing of equipment and materials is completed at our ISO 9001:2015 certified facility to ensure that the solution appropriately supports your operation and that the product, equipment, facility, and operators are supported by the right safety measures. Sensors, fall arrest, and motor amperage management, for example, are integral components of the design and operations.


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Custom Automated Storage & Retrieval

Large unit load ASRS for construction industry

Certain industries, often in the aerospace or manufacturing sectors, face unique applications or situations that require custom storage development whether due to size, weight, or process needs. While some challenges may be resolved with traditional or turnkey storage options, some require a more custom approach. Such challenges may include:

  • Large or bulky product loads
  • Sensitive or delicate products
  • Precise handling requirements
  • Harsh or freezer environments
  • Maneuverability with tight tolerances
  • Facility location and environment (e.g., earthquake regions)

Extreme environments

Custom automated storage solutions can be designed to work in specific spaces and temperatures. Aircraft manufacturers, for example, often handle delicate or sensitive materials, like carbon fiber, that require cold storage environments with below freezing temperatures of -20° F.

Bastian Solutions’ custom automation group has engineered VLMs that not only fit within specified parameters but also feature the necessary freezer-rated components for consistent, reliable operation.

Precise and delicate handling

Accounting for high weight capacities in addition to delicate and low tolerance handling can be challenging. Bastian Solutions custom designs and engineers automated storage solutions that can handle high weight capacities as well as varying flatness tolerances – 0.25 inches (6.35 mm) or 0.1 inches (2.54 mm), for example.

A heavy duty VLM designed for an aircraft manufacturer was designed to handle 20 steel molds weighing 7,100 lbs (3,220 kg) each for a total of 142,000 lbs (64,410 kg). Additionally, the location of the facility required the installed equipment also account for potential earthquake hazards.

Custom designed and built freezer-rated automated storage


To meet both your storage needs and business objectives, it’s key to consider:

  • Precise handling needs
  • Product characteristics
  • Workspace ergonomics
  • Safeguards and safety mechanisms
  • Storage capacity needs
  • Product environment requirements
  • Ease of install and maintenance
Heavy Duty Vertical Lift Module

The Bastian Solutions’ custom automation team works with customers to determine feasibility and return on investment of all possible custom solutions. We use three main tools during the engineering and fabrication phase: 


Engineering Studies 

 By investigating your existing processes and exploring different configurations, we’re able to engineer the best custom solution.


Machine Simulations

 We create realistic models of your proposed operation using real-world data, rates, speeds and the logic associated with handling products.


Finite Element Analysis 

For large structural loads or precise handling requirements, we can test for the proper strength, rigidity or flexibility to reduce risks and confirm capabilities.




By demonstrating excellence for standardization and quality assurance in our manufacturing process and for our commitment to customer experience and satisfaction, Bastian Solutions’ custom automation division has achieved ISO 9001:2015 certification.

By responsibly managing the environmental impact of our manufacturing processes to improve our environmental performance and for our commitment to sustainability, Bastian Solutions’ custom automation division has achieved ISO 14001:2015 certification


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custom heavy duty VLM

Case Study: Custom Heavy Duty VLM


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