Daifuku Mini Load

Maximize floor space with high density storage

Daifuku's mini load Automated Storage and Retrieval System (ASRS) is fast speed high density storage system that maximizes use of available cube space. The mini load moves and stores goods or parts placed in their original packing or if odd shaped that have been placed in totes or a standard carton. Items are sent to and taken from the mini load most commonly by conveyors or Automatic Guided Vehicle (AGV) or mobile robots.

Interested in Daifuku Mini Load AS/RS or want to know more?


How It Works

The Mini Load ASRS is operated by a crane mast that travels up and down the aisle while a load handling device travels vertically on the mast and can also reach into the rack to deposit or pick up a carton. Cartons are generally brought into the ASRS via conveyors to a pick up station where the ASRS load handling device will grab the pallet. The load handling device is generally a shuttle fork, side belt or side clamp.

Once the carton is secured the ASRS crane will travel to the correct lane location while the mast raises or lowers to the proper row height. Once at the proper lane location and row height the load handling device extends and drops the carton off in the rack for storage. The carton will be stored in the ASRS until it is ready to be retrieved. Once the retrieve command is sent to the ASRS the process will be reversed with the ASRS going to the proper lane and row location, retrieve the product then take it to a drop off location. After the carton is dropped off a conveyor system often takes the carton to the next process.


  • Load weight capacity: 30-300 kg (66-662 lbs.)
  • S/R machine height: 3-26 m (10-66 ft.)
  • Horizontal speed: 100-300 m/min. (328-984 ft./min.)
  • Vertical speed: 40-160 m/min. (131-525 ft./min.)
  • Shuttle speed: 20-100 m/min. (66-328 ft./min.)
  • Load footprint: 260-1500 mm x 350-1000 mm (10.2-51.9 in. x 13.8-39.4 in)

The above specs may vary depending upon individual system configurations and custom modifications may be available to better meet your exact application. The availability of overhead space in your specific facility will determine the height of the racking which may be used. Aisle length and the number of aisles available for use in your facility are based on your available floor space and building layout. Load size and throughput requirements do affect the speed of the ASRS system and are also considered when determining ASRS configuration.

Features & Benefits

  • Quiet operation
  • Variable acceleration rates
  • Ergonomic workstation
  • Flexible design allows for easy expansion
  • Improved throughput
  • Regained floor space
  • Inventory accuracy and control
  • High-speed stable storage/retrieval operation
  • Increased productivity
  • Reduced operator fatigue
  • Employee safety

Industries and Uses

Effective in forward pick operations, a mini load is also suited for applications that include the buffering and storage of small raw materials and/or finished goods. It is also a good buffering system for small items that represent work-in-process. Mini Load offers three crane transfer options to handle placement and retrieval of loads, whether items are in plastic totes, corrugated paper cases or a specialty container.

Floor space

  • Facility is full; no additional storage space
  • Plans for a new facility
  • Congestion; product stored in aisle and hallways
  • Need more space for production


  • Bottlenecks in material flow and production
  • Limited capacity in storage and production areas
  • Orders are becoming smaller and more frequent
  • Pick cycle times are too long


  • Frequent lost stock
  • Inventory Spoilage / Damage
  • No real-time material control
  • Poor product accessibility
  • Lack of FIFO control


  • Workers in hostile environments
  • Workers walking long distances
  • Excessive stooping and bending and reaching to pick product
  • Excessive noise levels from material handling equipment
  • Safety hazards
  • Labor-intensive processes

Disjointed Operations

  • Product in the wrong storage medium
  • Multiple staging areas
  • Product is often moved from one staging area to another


  • High employee turnover
  • High labor costs
  • High training costs
  • Small labor pool


Interested in Daifuku Mini Load AS/RS or want to know more?