Automated empty crate storage

Automated empty crate storage uses mechanical systems, conveyors, and purpose-built storage structures to handle, stack, and buffer plastic crates without manual intervention. These systems replace repetitive physical labour with reliable, programmable automation that keeps crates moving efficiently through a facility. Nekos is an international provider of automated material handling and intralogistics systems, including plastic crate and tote storage solutions, stacking and destacking equipment, and conveyor-integrated automation for food, beverage, retail, and industrial facilities. Below, we answer the most common questions about how these systems work, what options exist, and how to choose the right one.

How does automated empty crate storage work?

An automated empty crate storage system receives incoming crate stacks, organises them into defined positions within a storage structure, and releases them on demand to downstream processes. The system uses conveyors, stackers, destacking units, and control software to manage the entire flow without manual handling at each step.

In practice, crate stacks arrive from production or a wash line and are fed onto an intake conveyor. A stacking unit builds stacks to a consistent height, and the storage mechanism places them into rows or lanes within the designated storage area. When crates are needed at a filling or packing station, the system automatically retrieves a stack, destacks it to the required height, and delivers individual crates to the operator or the next automated station.

The control system monitors how many crates are available at any given moment, balancing the flow between incoming and outgoing streams. This buffer function is one of the most valuable aspects of automated tote storage: it absorbs fluctuations in production speed and prevents both bottlenecks and shortages at critical points in the line.

What types of automated crate storage systems are available?

The main types of automated empty crate storage systems are floor-level stack storage, vertical lift storage, and conveyor-integrated buffer lanes. Each suits different facility layouts, throughput requirements, and ceiling heights.

Floor-level stack storage

This approach places stacked crates in consecutive rows directly on the warehouse floor. Our LT Storage (Logistic Tote Storage) system is a patented example of this type: it maximises floor area utilisation by arranging stacks in tight, sequential rows and requires as little as 650 mm of clearance above the stack height. It is particularly well suited to facilities with low ceilings and is widely regarded as the most cost-effective crate storage solution available.

Vertical lift and conveyor-integrated systems

Vertical lift systems use height rather than floor area to store crates, which suits facilities with tall ceilings and a limited footprint. Conveyor-integrated buffer lanes are a lighter-weight option where stacks move along powered roller or belt conveyors in a first-in, first-out sequence. These work well as short-term buffers between a wash line and a filling station rather than as large-volume storage solutions.

How much storage capacity can an automated crate system hold?

Storage capacity depends on the system type, the available floor area or ceiling height, and the crate dimensions. Floor-level stack storage systems can typically hold hundreds to several thousand crates within a compact footprint, while vertical systems scale capacity upward by adding height rather than floor space.

The more useful measure for most production managers is buffer time: how many minutes or hours of supply the storage holds relative to the line’s throughput. A system processing 1,000 crates per hour needs a meaningfully larger buffer than one running at 600 per hour to maintain the same operational safety margin. When planning capacity, it is worth calculating peak demand rather than average demand, since storage is most valuable precisely when flows are uneven.

What’s the difference between automated and manual crate storage?

The key difference is that automated crate storage moves and positions crates using mechanical systems and control software, while manual storage relies on workers to carry, stack, and retrieve crates by hand. Automation removes the physical burden, reduces error, and enables consistent throughput regardless of staffing levels.

Manual crate storage creates several operational vulnerabilities. Workers carrying heavy stacks face ergonomic strain and injury risk. Flow rates depend entirely on how many people are available and how quickly they can work, which makes throughput unpredictable during shift changes or absences. Storage organisation also tends to deteriorate over time as crates are placed wherever space appears to be available.

Automated systems address all of these issues directly. Crates are always stored in defined positions, retrieved in a controlled sequence, and delivered at a consistent rate. The result is a more predictable production environment, lower physical strain on staff, and better use of floor space because the system places stacks precisely rather than approximately.

What industries use automated empty crate storage?

Automated empty crate storage is used most widely in food and beverage production, retail distribution, and general industrial manufacturing. Any operation that circulates reusable plastic crates at high volume benefits from automating the storage and handling of those crates.

In food production, crates move continuously between washing, filling, and dispatch, making a reliable buffer essential to line efficiency. Retail and logistics operations handle enormous volumes of crates across distribution centres, where manual handling at scale becomes impractical. Industrial manufacturers use automated tote storage to support assembly and kitting processes where parts are delivered in crates to workstations.

The common thread across all these sectors is high crate volume, repetitive handling cycles, and a need to keep crates available at the right place and the right time without tying up labour in purely physical tasks.

How do you choose the right automated crate storage system?

Choosing the right automated crate storage system comes down to four factors: available space and ceiling height, required storage capacity and buffer time, throughput speed, and integration with the rest of your handling line.

• Space and ceiling height: Low-ceiling facilities benefit most from floor-level stack storage systems that maximise horizontal density. Tall facilities with limited floor area are better served by vertical storage approaches.
• Capacity and buffer time: Calculate how many crates you need to hold at peak demand, not average demand. Factor in the time it takes to replenish the storage from upstream and drain it to downstream stations.
• Throughput speed: Match the system’s intake and retrieval speed to your line’s peak crate consumption rate. A system that cannot keep up during peak hours creates the same bottleneck as no system at all.
• Line integration: The storage system must connect cleanly to your conveyor type, stacker and destacker units, and any wash line or filling station. Modular systems that use standard conveyor interfaces are easier to integrate and expand later.

It also helps to think about the full lifecycle of the system: ease of maintenance, availability of spare parts, and whether the supplier can support you if something goes wrong. A storage system that sits at the heart of your production flow needs to be reliable above all else, so choosing a supplier with a proven track record in your industry is as important as the technical specification itself. If you are at the stage of evaluating options or planning a new installation, contact Nekos to discuss your crate storage and handling requirements — their team works with facilities internationally to design and deliver automated intralogistics solutions tailored to specific production environments.