VNA Warehouse: How it's Made & Benefits

A Very Narrow Aisle (VNA) warehouse is a type of warehouse that maximizes the utilization of floor space by saving aisle space. VNA racking systems make it possible to utilize more of the available floor space, accommodating high-density storage needs while maintaining efficient access to goods. This guide provides a detailed, step-by-step explanation of how to design and build a VNA warehouse, outlining the key considerations and strategies required for success.

What is VNA Racking Systems

A VNA racking system is a solution that maximizes warehouse storage by significantly reducing aisle widths compared to traditional pallet racking. With aisles typically between 1.5 and 1.9 meters wide, this system allows for increased pallet positions within the same footprint, making it ideal for high-volume storage operations. The racking structures in VNA warehouses are typically designed to accommodate pallets or smaller items, enabling flexible storage configurations.

Unlike conventional racking systems, which have wider aisles (3 to 4.5 meters), VNA racking requires specialized handling equipment such as trilateral or bilateral turret trucks and automated storage and retrieval systems (AS/RS). These machines are designed to maneuver effectively in the narrow aisles, ensuring that goods can be quickly retrieved and stored without disruption.

Key Benefits of VNA Warehousing

Building a VNA warehouse brings several notable advantages:

• Maximizes Storage Capacity: By reducing aisle widths, a VNA warehouse can increase storage capacity by up to 40% compared to standard racking systems.
• Direct Access to Goods: Despite the narrow aisles, VNA systems allow for direct access to products, speeding up order picking and inventory management.
• Efficient Use of Space: VNA warehouses are particularly beneficial in high-density operations, where maximizing every available square meter is critical.
• Automatable: VNA systems are highly compatible with automated solutions, such as AS/RS, which further enhance efficiency and reduce labor costs.

Planning and Designing a VNA Warehouse

When designing a VNA warehouse, there are several crucial factors to consider to ensure optimal functionality and storage capacity.

1. Space Optimization

The primary goal of a VNA racking system is to maximize the use of available space. This requires detailed planning and analysis of the warehouse layout. Begin by assessing the available floor space and determining the most efficient aisle configuration. Aisle widths should be minimized to between 1.5 and 1.9 meters, depending on the specific handling equipment to be used.

Additionally, it is important to consider the height of the warehouse. VNA racking systems are typically designed for high-bay installations, allowing you to stack pallets vertically. This increases storage density while maintaining accessibility.

2. Choosing the Right Racking Structure

Selecting the appropriate racking structure is critical to the success of a VNA warehouse. The racking units must be designed to accommodate the type of goods being stored, whether these are pallets or small boxes. The racking system should be adjustable to allow for storage flexibility, particularly if the warehouse will handle a variety of product sizes.

High-strength materials are recommended to ensure the durability of the racking system, especially in high-bay applications where heavy loads are common. Racks should also be designed to integrate seamlessly with any automated systems, such as AS/RS, that will be implemented in the warehouse.

3. Handling Equipment for VNA Warehouses

One of the main challenges in operating a VNA warehouse is the need for specialized handling equipment capable of maneuvering in the narrow aisles. The most common types of equipment used in VNA warehouses include:

• Trilateral Turret Trucks: These trucks have rotating forks that allow them to handle pallets on either side of the aisle or frontally. They are ideal for high-density storage environments and can deposit pallets directly onto the floor.
• Bilateral Turret Trucks: With telescopic forks housed in a cradle, these trucks can operate in even narrower aisles. However, they are unable to place pallets on the floor and require specialized racking configurations.
• AS/RS Trilateral Stacker Cranes: For fully automated operations, trilateral stacker cranes can be used to handle pallets in three positions (one frontal and two lateral), allowing for seamless storage and retrieval in narrow aisles.

Selecting the appropriate handling equipment depends on the volume of goods to be moved and the degree of automation required. For high-turnover operations, integrating autonomous mobile robots or shuttle systems may also be beneficial.

Implementing Automation in a VNA Warehouse

Automation is becoming an increasingly popular choice in VNA warehouses due to its ability to improve efficiency, reduce labor costs, and minimize human error. One of the most effective ways to automate a VNA warehouse is through the use of Automated Storage and Retrieval Systems (AS/RS).

1. AS/RS Integration

AS/RS systems, specifically trilateral stacker cranes, are designed to operate within the narrow aisles of VNA racking. These cranes are capable of autonomously picking up and placing pallets in three positions, enabling faster movement of goods and reducing the risk of accidents or damage.

By automating the storage and retrieval process, businesses can achieve higher throughput, reduce the need for manual labor, and increase the overall accuracy of their inventory management systems. AS/RS systems are also highly scalable, making them ideal for growing businesses looking to expand their operations.

2. Conveyor Systems and Robotics

In addition to AS/RS, businesses can further enhance automation by implementing conveyor systems and autonomous mobile robots (AMRs). Conveyor systems can transport goods to and from the aisles, reducing the need for manual handling. AMRs, on the other hand, can be programmed to pick and deposit items at various locations within the warehouse, further optimizing the order fulfillment process.

Fix Common Challenges in VNA Warehouses

While VNA warehouses offer numerous benefits, there are also several challenges to consider during the planning and implementation stages.

1. Specialized Equipment Costs

One of the main challenges of operating a VNA warehouse is the high cost of specialized handling equipment. Trilateral and bilateral turret trucks, as well as AS/RS systems, represent a significant investment. However, the long-term benefits, including increased storage capacity and improved efficiency, typically justify the initial expense.

2. Training and Safety

Operating within narrow aisles presents additional safety risks, particularly if manual forklifts are used. It is essential to provide comprehensive training for forklift operators to ensure they can navigate the aisles safely. Additionally, installing guidance systems, such as mechanical or wire-guided solutions, can help reduce the risk of accidents by ensuring the forklifts remain within the designated aisles.

Wire-guided systems, in particular, use a magnetic field generated by an embedded wire in the floor to guide the forklift’s movement, ensuring precise navigation in narrow spaces.

3. Battery Maintenance

Electric-powered handling equipment, such as turret trucks and AS/RS cranes, require regular battery maintenance to ensure uninterrupted operation. It is important to establish a routine maintenance schedule and have spare batteries on hand to minimize downtime during recharging.

Pros and Cons of VNA Racking Systems

Pros of VNA Racking System

• Space Optimization: The most significant advantage of VNA racking is the increased storage capacity it offers by reducing aisle widths.
• High Throughput: With direct access to goods, order picking and putaway times are reduced, increasing warehouse productivity.
• Automation Compatibility: VNA racking systems are easily automatable, enabling businesses to integrate advanced technologies such as AS/RS and autonomous robots.
• Versatility: VNA systems can accommodate a wide range of items, from large pallets to small boxes, making them suitable for a variety of industries.

Cons of VNA Racking System

• Specialized Equipment Requirements: The narrow aisle configuration necessitates the use of specialized handling equipment, which can be costly to purchase and maintain.
• Training and Safety Concerns: Operating in such tight spaces requires careful training and the implementation of safety measures to prevent accidents.

Final Thought

For companies seeking high-density storage, the VNA racking system provides a flexible, scalable, and high-performing solution. If you would like to get a quote or inquire about a VNA racking system, don't hesitate to contact us now, our team of experts is ready to find the best fit for your warehouse.