Yes, in many cases an old warehouse can be upgraded to ASRS. The real issue is not simply the age of the building, but whether the existing site can support a practical automation layout, stable equipment operation, and efficient material flow.
For many companies, upgrading an existing warehouse is more realistic than building a new one. It can reduce expansion pressure, improve space utilization, and help connect storage more closely with production, picking, or shipping.
What Should Be Evaluated First?
Before deciding whether an old warehouse can be upgraded to ASRS, several points should be reviewed:
available building height and usable footprint
floor load and structural conditions
pallet size, load, and storage profile
SKU profile and throughput requirements
inbound and outbound workflow
connection with production or shipping
software and control integration needs
A retrofit project is usually more feasible when the warehouse still has usable height, stable structure, and clear operating requirements.
Why Pallet Shuttle ASRS Is Often Suitable for Retrofit
For many existing warehouses, a pallet shuttle AS/RS solution is often easier to adapt than conventional layouts because it reduces aisle dependence and makes better use of vertical space.
It is especially suitable for projects that require:
higher pallet density within a limited footprint
better use of existing building height
lower dependence on manual handling
more controlled inbound and outbound flow
stronger inventory visibility and traceability
For retrofit projects, this flexibility is important. It allows companies to improve storage density and efficiency without automatically moving to a new building.
Project Reference
In one DELIECN project for a discrete manufacturing enterprise, the customer needed a denser and more efficient storage solution for welding wire drums while also improving the link between warehousing and production.
DELIECN delivered a pallet four-way shuttle AS/RS solution integrating shuttle robots, level-changing lifts, conveyors, a depalletizing system, WMS, flexible cranes, and gantry robots. The system supported automated inbound and outbound flow and allowed denser storage within the available warehouse footprint.
After retrieval, drums could be connected with AGVs and delivered directly to welding workstations, helping improve storage efficiency, reduce manual intervention, and strengthen the connection between storage and line-side supply.
FAQ
Can every old warehouse be upgraded to ASRS?
Not always. The feasibility depends on building height, structure, floor load, pallet profile, and operating requirements.
Why is a pallet shuttle system often suitable for old warehouse upgrades?
Because it can improve storage density within the existing footprint, reduce aisle dependence, and make better use of available building height.
Does warehouse retrofit only improve storage density?
No. A retrofit can also improve handling efficiency, inventory control, traceability, and coordination with production or shipping.
When is upgrading an old warehouse better than building a new one?
It is often a practical choice when the existing building still has usable structure and height, but storage demand, handling efficiency, or process control need to be improved.
CTA
If your warehouse is aging but storage pressure keeps increasing, building a new facility may not be the only answer. A pallet shuttle AS/RS upgrade may help you use the existing site more efficiently.
Talk to our team about your warehouse conditions and retrofit requirements.
