VLM vs. Pallet Racking: The Ultimate Showdown of Cost, Space & Efficiency
When you’re planning a warehouse optimization or expansion, you face a critical decision: stick with traditional pallet racking or invest in a modern automated solution like a Vertical Lift Module (VLM)?
This is more than just an equipment choice; it’s a decision that will impact your operational efficiency, costs, and competitiveness for years. To help you make the most informed decision, we’ve staged an ultimate showdown, comparing the two systems across four key battlegrounds.
Round 1: Space Utilization
- Pallet Racking: A notorious space-waster. To accommodate forklifts and personnel, wide aisles can consume nearly 50% of your total warehouse area. Furthermore, fixed shelf heights mean you are constantly paying to store “air,” as your goods rarely fill the entire vertical space of a bay.
- Infismash VLM: A master of density. The VLM pushes storage density to its physical limits, reducing the required floor space by up to 90%. Its intelligent system uses height detection to arrange internal trays dynamically, ensuring every inch of vertical space is utilized.
Winner: Infismash VLM. In today’s market where every square foot costs, the VLM’s advantage in space utilization is overwhelming.
Round 2: Order Picking Efficiency
- Pallet Racking: Relies on the inefficient “person-to-goods” model. Employees walk long distances, search for the right location, verify part numbers, and then bend or reach to retrieve items. This process is slow, physically demanding, and a breeding ground for errors.
- Infismash VLM: Employs the highly efficient “goods-to-person” model. The operator simply selects the required item on a screen, and the VLM’s high-speed extractor delivers the correct tray to an ergonomic access bay in seconds. Picking productivity is typically boosted by 200-400%.
Winner: Infismash VLM. The dramatic increase in efficiency translates to faster order fulfillment and lower labor costs.
Round 3: Inventory Accuracy & Security
- Pallet Racking: Open-style storage creates numerous problems. Items can be easily misplaced, damaged, or contaminated by dust. Inventory counts are a massive, disruptive manual effort that is rarely accurate.
- Infismash VLM: Functions like a secure vault. Its fully enclosed steel structure protects goods from the external environment. Every transaction is logged by the software, keeping inventory data updated in real-time with 99.9%+ accuracy. User access controls ensure that only authorized personnel can retrieve high-value items.
Winner: Infismash VLM. It provides an unparalleled level of inventory control and security.
Round 4: Long-Term Cost & Return on Investment (ROI)
- Pallet Racking: Low initial purchase price. However, the long-term costs are high: continuous rent for the large footprint, higher labor costs due to inefficiency, and financial losses from picking errors and damaged inventory.
- Infismash VLM: Higher initial investment. But it delivers a powerful return by saving massive amounts on facility space, reducing labor requirements, and eliminating the costs associated with errors. Most companies see a full return on their investment within 12-24 months.
Winner: Infismash VLM. It is a strategic investment that pays for itself and continues to deliver savings for years.
| Comparison Metric | Traditional Pallet Racking | Infismash VLM |
| Space Utilization | Low, wastes significant floor & vertical space | Excellent, saves up to 90% of floor space |
| Picking Efficiency | Low, “person-to-goods” | Excellent, “goods-to-person” |
| Inventory Accuracy | Low, relies on manual counts | 99.9%+ Accuracy, real-time updates |
| Product Security | Poor, open-air storage | Excellent, fully enclosed and secure |
| Long-Term ROI | Low, high ongoing operational costs | High, typically returns investment in 1-2 years |
What’s Your Next Move?
If your goal is to build a lean, efficient, and future-proof operation, the choice is clear.
Want to see exactly how a VLM would perform in your specific application?
Contact us today, and our automation experts will provide a detailed ROI analysis tailored to your business.