Vertical Lift Module System (VLM): A Comprehensive Guide
A Vertical Lift Module (VLM) is a type of automated storage and retrieval system (ASRS) designed to optimize vertical space in warehouses, factories, and distribution centers. It consists of two columns with trays stored between them and an automated extractor that delivers the requested tray to an access point.
The core idea behind VLMs is to reduce floor space usage while increasing storage capacity. As warehouse space becomes more expensive and businesses demand faster order fulfillment, VLM systems offer a smart way to store and retrieve items efficiently and safely.
These systems are most commonly used in industries like manufacturing, logistics, healthcare, and retail—where quick access, accurate inventory management, and space-saving are critical.
Why VLM systems are important today
In modern supply chain and logistics operations, speed, efficiency, and accuracy are essential. VLM systems provide solutions to several challenges faced by companies handling physical inventory.
Key benefits and problems VLMs help solve:
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Maximizing space: VLMs can save up to 85% of floor space by using vertical room.
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Improving accuracy: Automated retrieval reduces human picking errors.
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Enhancing productivity: Workers spend less time walking and searching for items.
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Increasing safety: Reduces risk of injury by bringing items to ergonomic height.
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Supporting inventory control: Many VLMs integrate with warehouse management software (WMS).
Who is affected or benefits from VLMs?
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Warehouse operators and logistics firms
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Manufacturing plants storing components
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Hospitals and pharmacies managing medical supplies
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E-commerce retailers requiring high-speed order fulfillment
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Aerospace and automotive industries with large inventories
As businesses grow and labor becomes more expensive, the demand for automation tools like VLMs continues to rise.
Recent updates and trends in VLM technology (2024–2025)
In the past year, the VLM industry has seen innovation driven by digital transformation, sustainability goals, and the need for faster throughput in e-commerce and industrial supply chains.
| Trend/Update | Description |
|---|---|
| AI integration | VLMs are now using artificial intelligence to optimize storage slotting and picking paths. |
| IoT-enabled monitoring | Sensors track machine performance and inventory in real-time. |
| Modular scalability | New VLM systems can be easily expanded as storage needs grow. |
| Energy-efficient motors | Manufacturers are introducing eco-friendly drives to reduce energy consumption. |
| Cloud-based WMS | Cloud integration allows VLMs to communicate with other systems in multi-site operations. |
In 2025, companies such as Kardex and Modula introduced next-generation VLMs with robotic arms for automated picking and touchscreen interfaces that allow workers to manage inventory without training on complex software.
Regulations and policies that impact VLM use
While there are no global laws that govern the use of VLMs specifically, several standards and regulations apply to their design, safety, and data integration, especially in sectors like manufacturing, healthcare, and logistics.
| Regulation/Standard | Area | Relevance to VLM Systems |
|---|---|---|
| OSHA (USA) | Worker safety | Ensures ergonomic operation and safe machinery usage. |
| CE Marking (EU) | Equipment safety | VLMs in Europe must meet machinery safety requirements. |
| ISO 9001 | Quality management | Encourages use of efficient storage solutions for quality control. |
| HIPAA (USA) | Healthcare privacy | Medical VLMs must secure access to patient-related items. |
| FDA compliance (USA) | Medical storage | Systems used in pharma must meet regulatory conditions. |
In certain jurisdictions, local fire and building codes may also dictate how high a VLM can be installed or how much weight each tray can hold. It's important for organizations to verify compliance before installation.
Helpful tools and resources related to VLM systems
There are several tools and resources available for planning, managing, and learning about VLM systems.
Planning Tools:
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Storage capacity calculators – Estimate how much space a VLM can save.
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Warehouse layout design tools – Create efficient warehouse blueprints.
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ROI calculators – Assess return on investment for automated storage.
Educational Resources:
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MHEDA – Material Handling Equipment Distributors Association
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MHI.org – Industry news and whitepapers on automation and VLMs
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YouTube videos and manufacturer webinars on installation, use, and maintenance
Software and Apps:
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Warehouse Management Systems (WMS) that support VLM integration:
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Oracle NetSuite WMS
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SAP Extended Warehouse Management
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Fishbowl Inventory
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Apps for remote inventory monitoring and real-time alerts via mobile devices
These tools help businesses make informed decisions about selecting and integrating a VLM into their operations.
Frequently Asked Questions (FAQs)
1. What is the difference between a VLM and a vertical carousel?
A VLM uses an extractor to retrieve trays from two vertical columns and deliver them to an access point, while a vertical carousel rotates shelves like a Ferris wheel. VLMs are usually faster, more flexible, and better suited for heavier loads.
2. How much floor space can a VLM save?
VLM systems can reduce floor space requirements by up to 85% compared to traditional shelving or racking. The actual savings depend on the building's ceiling height and layout.
3. Can VLMs handle heavy or bulky items?
Yes. Many VLMs can support trays weighing up to 1,000 kg (2,200 lbs) or more. They’re ideal for storing both small components and heavy machine parts.
4. Are VLMs suitable for small businesses?
While VLMs are more common in large-scale operations, modular and compact models are becoming increasingly accessible for small businesses, especially in industries with limited space or high-value inventory.
5. Do VLMs require special maintenance?
Like all automated systems, VLMs need periodic inspections and servicing to maintain performance. Most systems have built-in diagnostics and alerts that simplify maintenance.
Summary comparison: VLM vs. traditional shelving
| Feature | Vertical Lift Module (VLM) | Traditional Shelving |
|---|---|---|
| Space efficiency | High (vertical storage) | Moderate |
| Access speed | Fast, automated | Manual, slower |
| Safety | Ergonomic and enclosed | Requires physical reaching/lifting |
| Security | Controlled access | Open access |
| Cost | Higher upfront, lower long-term | Lower upfront, more labor-intensive |
Final thoughts
Vertical Lift Module (VLM) systems offer an efficient, modern approach to storage and retrieval across various industries. Their ability to save space, improve picking accuracy, and enhance worker safety makes them a valuable asset in today's fast-moving logistics and manufacturing environments.
As industries continue to prioritize automation and efficiency, VLM systems are expected to grow in popularity. With the right planning, integration tools, and regulatory compliance, VLMs can provide long-term benefits for organizations of all sizes. Whether you're exploring automation for the first time or upgrading an existing system, understanding how VLMs work is a strong step forward in smarter warehouse and inventory management.
