Rethinking Efficiency: How Daifuku’s Advanced AS/RS Solutions Are Transforming Intralogistics

Since the introduction of its first Automated Storage and Retrieval System (AS/RS) in 1966, Daifuku has remained at the forefront of material handling innovation. Today, with more than 34,000 ASRS cranes delivered across the globe, Daifuku continues to lead the way in transforming warehouse and production environments through automation that is built to last and tailored for performance.

From freezer-ready facilities to high-capacity shuttle systems, our solutions are not only built to meet today’s challenges they’re engineered for tomorrow’s demands.

In this blog article, we take a closer look at our journey in automation, explore key AS/RS technologies, and highlight how our approach ensures exceptional flexibility, reliability, and operational gains for every customer.

A Legacy of Innovation

Daifuku’s commitment to continuous improvement and long-term reliability dates back nearly six decades. When we launched our first AS/RS in 1966, we envisioned a future where automation could optimize space, increase safety, and improve accuracy within the warehouse. That vision still drives us today.

Our systems are built to last, some have been operating reliably for more than 50 years. This remarkable longevity reflects the excellence of our engineering, robust maintenance strategies, and our unwavering commitment to customer success

In 1973, we designed and deployed our first freezer-capable AS/RS, which operated in environments as cold as -40°F (-40°C). While our current standard product line is rated to -30°C, we continue to offer customized solutions capable of reaching -40°C when required. Shortly after that initial installation, we built a large-scale refrigerated AS/RS featuring 20 storage and retrieval machines—a system that remains in operation today. These milestones highlight our long-standing commitment to innovation and the trust our customers place in Daifuku as a reliable, long-term partner.

Why One-Size-Fits-All Doesn’t Work

A key differentiator of Daifuku Intralogistics America is our belief in tailored automation. Cookie-cutter solutions simply don’t work in environments where unique products, storage needs, and workflows demand specialized approaches.

That’s why we take the time to analyze each client’s operations, infrastructure, and goals. Whether you’re handling pallets, trays, long items, auto bodies, or anything in between, our ASRS systems are engineered for precise, purpose-built performance. This custom-fit philosophy ensures our clients gain real-world advantages today and into the future.

As Andrew Sawyer, Manager of System Engineering at Daifuku Intralogistics America, puts it: “One of the most important things to know about Daifuku Intralogistics America is we don’t believe in one-size-fits-all solutions.”

Watch our Innovation Center video to see this philosophy in action and explore how our tailored automation solutions meet real-world challenges.

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AS/RS Solutions That Deliver More

Unit Load ASRS

Daifuku's Unit Load ASRS is one of the most trusted and field-proven solutions available in the market. With over 34,000 cranes delivered globally, our expertise in unit load handling spans industries from food and beverage to automotive, cold storage, and pharmaceuticals.

Key Features:

• Multi-depth storage: Configurable for single, double, or up to eight products deep storage.

• Towering height: Capable of reaching up to 40 meters (~130 feet)—ideal for high-density, rack-supported building designs.

• Extreme temperature readiness: Designed to operate in freezer environments as low as -30°C (-22°F).

• Flexible load capacity: Handles various loads including pallets, rolls, and auto bodies—up to 6,600 lbs per unit.

• High throughput: Options such as dual cranes in a single aisle allow the system to meet the needs of demanding applications.

What sets our Unit Load system apart is the engineering process behind each installation. Our team works closely with customers to understand their operational challenges and design a system optimized for their specific needs, be it in storage density, throughput, or environmental conditions.

Shuttle Rack Systems

For applications requiring smaller load handling, Daifuku’s Shuttle Rack solutions offer versatility, performance, and adaptability. These systems are ideal for case, tote, or tray-based workflows and are highly effective in goods-to-person picking, order fulfillment, and buffer storage applications.

Key Features:

• Single and double-deep storage configurations

• Maximum height of 18 meters (59 feet)

• Freezer-capable design, down to -30°C (-22°F)

• Supports load units up to 88 lbs

• Multi-format load handling within a single aisle, cases, totes, and trays

• Available with triple load lifters to increase throughput

The shuttle system’s modular architecture means it can scale easily with your business needs while optimizing throughput, accuracy, and energy usage.

Applications Across Industries

Daifuku’s AS/RS technologies are not just functional, they’re redefining the way supply chains operate across a variety of sectors.

Cold Storage and Food Processing

Cold environments are among the harshest for human workers, with labor availability and retention being a major issue. Our AS/RS systems for cold storage are designed to operate reliably in sub-zero conditions, helping companies maintain compliance, improve safety, and drastically reduce labor costs.

By maximizing vertical space and automating retrieval, we also reduce door openings, energy consumption, and temperature fluctuations, helping you achieve greater sustainability and operational savings.

General Warehousing and Distribution

For high-throughput warehouses, especially in e-commerce, pharmaceuticals, or third-party logistics, speed and accuracy are key. Shuttle systems provide multi-format handling and rapid order retrieval, while unit load cranes offer dense storage for larger SKUs.

Together, these systems help companies increase fulfillment speeds, reduce picking errors, and optimize labor efficiency in an increasingly competitive landscape.

Engineering for Sustainability

Sustainability is no longer optional it’s a business imperative. Daifuku’s AS/RS systems contribute to sustainability goals in several critical ways:

• Energy efficiency: Optimized travel paths and energy recovery systems reduce power consumption.

• Space utilization: Vertical systems reduce building footprints, cutting heating/cooling needs.

• Reduced waste: Automation improves accuracy and inventory control, lowering spoilage and overstock.

• Fewer emissions: Streamlined operations cut down on forklift traffic and fuel usage.

By enabling businesses to do more with less, our systems help customers advance both their operational performance and environmental responsibility.

A Partner in Your Automation Journey

Choosing the right AS/RS solution is only the beginning. At Daifuku Intralogistics America, we provide end-to-end support from initial consultation to custom engineering, integration, and long-term service. Our deep experience, global resources, and regional expertise make us a trusted partner for businesses of all sizes and industries.

We don’t just build systems; we build relationships grounded in understanding your goals and delivering measurable results.

Why Choose Daifuku?

• Proven reliability: Systems still running strong after 50 years.

• Custom-fit approach: Every solution is engineered to your unique needs.

• Global leader: 34,000+ ASRS cranes deployed worldwide.

• Comprehensive portfolio: Unit load, shuttle rack, freezer environments, and more.

• Focus on sustainability: Solutions that meet environmental and business goals.

Whether you're expanding a high-volume distribution center, optimizing cold storage, or rethinking your manufacturing logistics, Daifuku has the experience and technology to make your vision a reality.

Contact Daifuku Today

Looking to learn more about how our ASRS solutions can transform your operations?

Daifuku Intralogistics America is ready to help you build a smarter, more efficient, and more sustainable future.

Let’s talk about what automation can do for you.

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