Is it possible to streamline the storage space that I have always managed in a certain way? Where can one find solutions designed to optimise available square footage and volumes?
These are questions that many companies ask, especially when space management becomes increasingly critical. How do you address an entrenched situation where the requirements change rapidly?
When storing large numbers of products, while at the same time managing a dynamic business with constantly evolving needs, it is essential to adopt a flexible and intelligent approach. In this context, bin storage has proven to be one of the most effective and versatile solutions in modern supply chain management, offering adaptable space optimisation to meet various needs.
The Modula Flexibox stands out as one of the most innovative and reliable options on the market. This advanced smart solution goes beyond traditional technologies, offering exceptional flexibility, adaptability, and efficiency — particularly for businesses handling anywhere from a few hundred to several thousand bins.
Modula Flexibox: an innovative solution for automated bin storage
The Modula Flexibox is a cutting-edge automated storage solution designed to meet the evolving challenges of warehouse organisation and order picking. Using the Vertical Lift Module (VLM) principle, the Flexibox differs from conventional tray-type vertical automatic warehouse systems thanks to its dynamic approach. Instead of retrieving entire trays, picking is done from individual bins brought to the bay, which can also be segmented into different compartments within the same unit, thus optimising the picking process.
One of the Flexibox’s most distinctive technical features is its elevator, equipped with a telescopic fork that moves vertically at the centre of the machine, retrieving bins from both the front and rear columns of the warehouse.
The system includes:
- X-axis travel module: for lateral system movement.
- Y-axis lift module: for adequate vertical movement.
Thanks to these features, the Flexibox retrieves bins from the vertical warehouse’s columns one at a time and places them in the service tray. At the end of the cycle, the tray contains all the necessary bins (ranging from 4 to 9, depending on the model). This system significantly optimises batch picking and multi-order picking, reducing retrieval times and accelerating order fulfilment, making it ideal for intensive picking, kitting, and storage optimisation.
With standard dimensions of 600×400 mm (and in variable heights if needed), and a load capacity of up to 35 kg, the bins offer remarkable versatility, enabling efficient handling of a wide range of products.
How the Modula Flexibox is redefining warehouse efficiency
The Modula Flexibox represents a significant breakthrough in automated storage systems. Its ability to maximise space, accelerate picking, and enhance overall efficiency makes it an ideal solution for numerous applications. It is particularly well-suited for use in the e-commerce, retail, electronics, fashion, and pharmaceutical industries, as well as for production purposes for kitting operations, such as for the automotive, agriculture, mechanical engineering, and aerospace sectors.
But what are the key features that make the Flexibox such a valuable investment for companies that decide to adopt it?
1. Space optimisation without compromise
As mentioned above, the issue of floor space is one of the primary challenges companies face daily. The Flexibox is designed to maximise the use of vertical space, minimising the footprint on the ground as much as possible.
With its intelligent design and bin storage system, it significantly maximises the use of the available space, reclaiming up to 90% of the floor space occupied by traditional storage solutions.
This allows companies to store larger quantities of materials in a smaller space, without compromising on accessibility or the ability to accommodate material of different sizes and volumes.
2. Picking speed and accuracy
Picking speed is essential to ensuring customer satisfaction, particularly in industries where orders must be fulfilled with tight deadlines. The Flexibox offers a highly efficient solution, drastically reducing picking times thanks to automated bin management.
This advanced system achieves exceptional performance, handling up to 180 bins per hour, even processing multiple bins simultaneously. By streamlining operations, it increases the number of order lines processed, optimises picking cycles, and significantly reduces the number of movements required per pick.
The system also minimises human error and enhances accuracy by delivering the bins required to complete the order directly to the operator. This not only improves speed but also enhances traceability and security.
3. Ease of installation and scalability
One of the most common challenges when adopting new technology is complexity of installation. Many storage solutions require extensive structural modifications, or even new construction, leading to high costs and prolonged downtime.
The Flexibox stands out for its ease of implementation, requiring no major structural changes, and integrating seamlessly into existing spaces and systems. Moreover, its modular design allows for easy expansion of storage capacity based on business needs, allowing additional independent units to be incorporated over time, while remaining part of the same software ecosystem.
4. Reduced energy consumption
Energy consumption has become a major concern for companies operating in automated environments. The Flexibox is designed for high energy efficiency, contributing not only to cost savings, but also to enhanced environmental sustainability — an increasingly critical factor for modern businesses. As a testament to its efficiency, this storage system consumes just 1.2 kW/h, less than a typical hair dryer.
5. Seamless integration with WMS software
A key strength of the Modula Flexibox is its seamless integration within existing software ecosystems, particularly the Modula ecosystem. In fact, it can be effortlessly incorporated into environments where other Modula systems or warehouse management solutions are already in use, ensuring full compatibility and operational continuity.
Modula offers a range of software options to effectively manage its automated solutions:
- Modula WMS Base: a basic version, ideal for businesses seeking efficient management of the Modula system (including Flexibox) without requiring ERP integration or advanced functions.
- Modula WMS Premium: a more comprehensive solution, designed for integration with corporate ERP systems, making it ideal for complex and structured business environments.
- Modula Driver and Modula Link: tools that allow companies already using a WMS to connect directly to Modula systems, enabling seamless management of all activities within a single software environment, with no need to modify their existing systems.
With this level of flexibility, the Flexibox is not only an excellent choice for operational efficiency, but also for its ability to integrate into any pre-existing IT infrastructure in a seamless and modular fashion. Companies can thus benefit from an advanced system without facing costly and time-consuming reconfiguration processes, while at the same time maintaining full control over all their logistics activities.
Comparison with existing solutions: why the Modula Flexibox is the ideal choice
Various technologies are employed in daily warehouse management, focusing on effective space utilisation, improving the picking process, or enhancing overall efficiency. However, not all solutions are suitable for every type of warehouse or operational need.
Impact of the warehouse on the existing structure
As a concrete example, consider high-density AS/RS (Automated Storage and Retrieval System) solutions, such as those based on cubic storage technologies like AutoStore. Combining containers, mobile robots, grids, and control infrastructures, this type of system is highly efficient for intensive storage, and ideal for handling thousands of bins. However, it requires extensive structural modifications and lengthy implementation times.
In addition to requiring dedicated space, these systems also entail considerable investments — often millions of Euros — both for the infrastructure and for integration into the existing workflows. These solutions are most effective when managing extremely high volumes of products, making them more suitable for large-scale operations, such as e-commerce giants.
By contrast, the Modula Flexibox offers a more agile and flexible solution, ideal for businesses that need to manage a variable number of bins (ranging from a few hundred to several thousand) and are looking for a system that can be rapidly installed without requiring any structural modifications or prolonged downtime.
Impact of the warehouse on picking operations
Certain types of bin-type vertical warehouses or Miniload stacker cranes are effective for picking single containers, but these solutions can pose limitations when it comes to handling multiple orders simultaneously. The Flexibox, on the other hand, is designed to manage up to 9 bins at once, enabling optimised multi-order picking and significantly reducing picking times.
With the Flexibox, each bin is retrieved individually and transferred to the service tray, where the operator can efficiently pick the individual items needed for each order, thus enhancing order fulfilment speed while reducing picking errors.
| The Flexibox Solution | Vertical buffer module | Miniload system | AS/RS systems | |
| Storage type | Bin storage | Container storage | Container storage | Robotic cube storage |
| Space requirements | Low (optimised vertical space) | Low (optimised vertical space) | Medium (optimised vertical space) | High (requires considerable space and structures) |
| Structural modifications required | No structural modifications | No structural modifications | Some structural modifications | Major structural modifications |
| Picking speed | High (fast picking) | High (fast picking) | High (fast picking) | High (robotic speed) |
| Initial cost | Low (no structural interventions) | Medium (system cost) | Medium (system cost) | High (expensive for infrastructure) |
Bin storage and the Modula Flexibox: the new standard for the warehouse of the future
Today, there is a wide range of automated storage solutions available, each offering specific advantages for different sectors and applications. Thanks to its modularity and adaptability, the Modula Flexibox is the ideal choice for a broad spectrum of warehouses, from smaller operations to larger facilities with high storage density. It’s the perfect solution for businesses seeking a dynamic warehouse capable of evolving alongside their operational needs.
Choosing the Modula Flexibox means investing in a system designed to grow with your warehouse, continually adapting to any changes and new requirements that may arise. Its seamless integration with other technologies ensures a secure, long-term investment that’s ready to meet future challenges.
Ideas for warehouse reorganization
