Comparing Pick Module Systems: Static vs. Dynamic Configurations

Labor is the biggest expense in most warehouse operations budgets. Depending on which study you cite, picking accounts for between 36% and 55% of operating costs. Either way, it is substantial. With increased pressure to reduce costs, improve efficiency, and overcome labor shortages (and higher wages), warehouses, fulfillment centers, and distribution facilities are taking a hard look at warehouse pick modules for more efficiency.

Let’s take a look at static and dynamic pick module systems and how they can impact your operation.

Static Pick Modules

Static pick modules are fixed structures. Designed to optimize manual picking, these systems are generally made up of pallet racks, shelving, and conveyors in a multi-level configuration. They are ideal for warehouses with consistent products and order patterns, providing stability and predictability.

Key components generally include:

  • Selective pallet racks
  • Static shelving
  • Gravity-fed conveyors
  • Carton flow racks

Dynamic Pick Modules

Dynamic pick modules provide greater flexibility and automation. Designed to bring products to pickers, they are effective in high-volume warehouses or operations where space is limited. Dynamic pick modules can significantly improve throughput and reduce travel time.

Common components in a dynamic pick module system can include:

  • Horizontal/vertical carousels
  • Vertical lift modules (VLMs)
  • Automated storage and retrieval systems (AS/RS)
  • Robotic picking equipment

Comparing Static and Dynamic Pick Modules

Dynamic warehouse pick modules have higher costs due to their automation compared to static pick modules but also provide significant benefits. Here’s how the two approaches stack up.

Comparing Static and Dynamic Pick Modules
  STATIC PICK MODULES DYNAMIC PICK MODULES
SPACE UTILIZATION
  • Require large footprint
  • Offer good vertical space usage
  • Fixed layout limits space optimization
  • Maximize cubic space utilization
  • Ideal for facilities with limited floor space
  • Adaptable to space changes
THROUGHPUT
  • Consistent picking speed
  • Require pickers to travel to items
  • Suitable for steady order volumes
  • Higher picking speeds, especially for smaller items
  • Reduced picker travel time
  • Suitable for high-volume and high-SKU environments
FLEXIBILITY
  • Limited flexibility after installation
  • Scaling requires significant reconfiguration
  • Best for stable product lines
  • More adaptable for changing inventory
  • Can be scaled incrementally
  • Ideal for operations with a changing product mix
COSTS
  • Lower initial investment
  • Minimal maintenance costs
  • Few powered components (less energy usage)
  • Higher upfront cost
  • Increased maintenance of moving parts
  • Higher energy consumption
INVENTORY MANAGEMENT
  • Manual inventory tracking
  • Potential for errors in stock counts
  • Visual management of inventory
  • Automated inventory tracking
  • Higher accuracy in stock levels
  • Real-time inventory visibility

 

Pick Module System Integration

Both types of warehouse pick modules can integrate well with warehouse management systems (WMSs) or order management systems (OMSs), enabling operators to optimize picking routes, manage inventory, and monitor KPIs for performance. Dynamic systems will automate more of the process, however.

Which Pick Module System Is Right for You?

When selecting warehouse pick modules, there are several key factors to take into consideration depending on how you plan to operate. These include:

  • Current and project order volume
  • Mix of inventory
  • Existing storage configurations
  • Budgetary constraints
  • Labor availability and costs

Overcoming Warehouse Challenges

Many warehouse managers are struggling with filling jobs and controlling labor costs. Despite pay increases, turnover continues to be a consistent problem. The American Staffing Association forecasts there will be 1.7 million openings in warehouse and transportation in 2024, and that number is expected to grow to 2.1 million by 2030. Even with recent industry layoffs, it has become challenging to maintain the workforce.

Many warehouse operators are looking to transition to more dynamic pick modules as a result, adding automation to overcome labor shortages and payroll challenges. Gartner reports that there are already more than two million industrial robots in use. Further, they forecast that by 2028, there will be more smart robots and automation than frontline workers in warehouse operations.

Planning, Engineering, and Configuring Your Warehouse

The warehouse experts at Conesco Storage Systems can help you plan, engineer, and configure your warehouse for peak efficiency. We can provide an end-to-end solution, including layout and design, engineering plans and permitting, and project management services to meet your goals. As one of the leading distributors of new and used warehouse equipment, we can find the perfect fit whether you are considering static or dynamic pick modules.

Our team has more than 400 years of combined industry experience in new and used material handling equipment sales, warehouse planning strategy, engineering and permitting, installs, and transitions. No matter what configuration you need or the space you have to work in, we can create a warehouse that operates efficiently.

We can help you maximize your value, amplify your space, improve efficiency, and—most importantly —save you time and money. Request a free consultation to discuss your needs, timeline, and priorities. We will provide you with a custom proposal that works within your budget.

Call Conesco Storage Systems at (303) 690-9591 or request a free consultation to discuss your warehouse operations needs.

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Ted Hodges

Ted Hodges is the Founder and CEO of Conesco Storage Systems, a company he started in 1986 to provide turnkey warehousing products and services, including the repurposing of quality, used material handling equipment. With over 40 employees across the country, Ted and his team serve customers of all sizes throughout the different stages of the warehousing lifecycle. Learn more about Teddy.

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“Working with Conesco was great. They asked the right questions, understood what we needed and our Denver Facility went in under budget. Good guys, good prices, and good services.”
~ Multinational Grocery Supply Company
“We have worked with Conesco for over 8 years, they are leaders in the Racking Industry, exceptional customer service and great in every aspect to work with. I refer them to anyone I know with racking needs.”
~ Third Party Logistics [3PL] Customer
“Over the past few years Conesco has proven to be valuable partners for our growing company. They understand their market and the priorities of our business, often helping us stay ahead of changes in demand for new and used racking so that we can get what we want when we want it.  It is good to have a partner that can anticipate your needs and stay ahead of them, that is the level of service that Conesco has demonstrated on a regular basis.”
~ Third Party Logistics [3PL] Company

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