Automated storage and retrieval systems (ASRS) are computer-controlled warehouse solutions that use robotics and automated guided vehicles to manage inventory and distribution processes. A growing number of modern warehouses use ASRS to place and retrieve items from specified inventory and storage locations, improving speed, accuracy and space efficiency.
The benefits are significant: ASRS supports up to 99.9% inventory accuracy and up to 40% cost savings in warehouse operations. According to a recent Kardex research study on integrated warehouse systems, roughly 1 in 3 warehouses use ASRS and other advanced automation to support storage and picking operations.
These facilities can operate as “lights-out” environments, where ASRS robots function without lighting in reduced temperature control or even low-oxygen conditions to help lower energy and operating costs.
In these computer-controlled facilities, multiple doors must open and close hundreds of times per day. That’s a significant potential source of energy loss, especially in northern climates where the external temperature can vary by over 100 degrees between summer and winter – threatening the energy efficiency of environments inside these warehouses.
Purpose-Built for ASRS Environments
High-performance doors are the perfect complement to ASRS technologies, playing a key role in efficiency, energy control and uptime.
Thermal Performance in Alternate Environments. In ASRS environments, especially in cold storage, freezer applications or controlled atmosphere systems, temperature stability is everything. That’s why Rytec’s Sure-Seal® door is designed for non-live-traffic interior applications where speed, low maintenance and dependability are critical.
The Sure-Seal® door is engineered to minimize air exchange with fast cycle times that reduce the opportunity for thermal loss in facilities using an alternate atmosphere. Its insulated panel has excellent thermal properties, with an R-4 insulation value, helping support energy efficiency and maintain tight environmental control.
More thermal design features include:
- A non-porous, moisture-proof vapor barrier for consistent performance
- Laterally rigid and vertically flexible panel construction for sealing reliability
- A top vinyl loop seal that helps limit air leakage at the header
- A low-temperature bottom edge seal designed to reduce ice buildup and help prevent ice propagation
Energy Efficiency Through Tight Sealing and Fast Cycling. Efficiency in ASRS operations isn’t just about speed – it’s about reducing energy loss every time a door cycles.
Sure-Seal doors are designed with tight perimeter sealing and insulated panels that help reduce energy escape when closed. In high-cycle environments, even small improvements in sealing performance can translate into meaningful long-term energy savings. By minimizing infiltration and maintaining consistent internal temperatures, these doors help reduce strain on HVAC and refrigeration systems, supporting both operational efficiency and sustainability goals.
Seamless Integration with Building Controls. Modern warehouses rely on synchronized systems, and doors are no exception. The Sure-Seal door is built for efficient integration with ASRS control systems, featuring a standard I/O expansion board and compatibility with Rytec’s System 4+™ Controller, Rytec’s next-generation control system designed to simplify and enhance high-performance door operation.
The System 4 Controller uses intelligent processing and a variable frequency drive to deliver smooth acceleration, soft starts, and controlled stopping for reduced wear and improved efficiency. It features a user-friendly interface to easily adjust door functions, settings and positioning. It also supports advanced diagnostics and event tracking to improve energy efficiency and overall door performance in ASRS environments.
This flexibility allows the door to communicate directly with ASRS control systems, ensuring smooth coordination between retrieval equipment, conveyors and access points. The result is fewer delays, more predictable throughput and improved system reliability.
High-Speed, Low-Noise Operation. Some high-performance doors are engineered to open at speeds up to 100 inches per second, helping reduce wait times between automated cycles. Just as important, they’re designed for quiet operation, ideal for high-density warehouse environments where multiple systems run simultaneously. This fast, quiet movement helps maintain workflow continuity without adding unnecessary disruption to adjacent operations.
Built for Long-Term Durability. ASRS environments are demanding, especially in cold storage and high-cycle applications. Sure-Seal doors are built to withstand these environments to help optimize operational and energy efficiency. Engineered for repeated use and harsh environments, they deliver dependable operation over time while minimizing wear points that typically lead to downtime in conventional doors.
Designed for Oversized Openings. Warehouses are getting smaller in footprint but taller in design, and ASRS systems are being used to maximize this vertical storage capacity. High-performance doors can be custom manufactured to accommodate facilities that require large doors with wide and tall openings.
Contact us today to discuss how high-performance doors can improve productivity and energy efficiency in your ASRS facility.
