Automated Gantry Storage System for Profiles | Herochu Profile ASRS

Profiles—whether aluminum extrusions, steel angles, channels, or custom architectural sections—present unique storage challenges. Their length makes them unsuitable for standard pallet racks, their variety of cross-sectional shapes complicates gripping, and their susceptibility to bending or scratching demands gentle handling. The Herochu Automated Gantry Storage System for Profiles is engineered specifically to address these challenges. By combining a high-speed gantry with profile-specific tooling and intelligent software, this system transforms a chaotic profile storage area into an organized, accessible, and space-efficient automated warehouse.

Why Profiles Require Specialized Storage

Unlike round pipes, profiles have asymmetrical geometries. An aluminum T-slot extrusion, for example, has a flat back and protruding flanges. Placing such a profile on a standard flat shelf can cause deformation of the flanges over time. The Herochu automated gantry storage system uses profile cradles—custom-machined supports that match the profile’s shape. These cradles are removable and interchangeable, allowing the same shelf to accommodate different profile families on different levels. When the gantry retrieves a profile, it does not simply drag it horizontally; instead, a vacuum-assisted gripper lifts the profile vertically, then translates it. This eliminates scraping against shelf edges, preserving surface finish for anodized or painted profiles.

Speed and Throughput for High-Mix Environments

Profile warehouses often handle hundreds of different SKUs, with each order requiring a mix of lengths and alloys. Throughput depends entirely on how quickly the storage system can locate and retrieve each profile. The Herochu automated gantry storage system achieves a maximum travel speed of 50 m/min, twice as fast as conventional gantries (approx. 25 m/min). For a facility processing 300 picks per shift, this speed advantage reduces gantry travel time from roughly 150 minutes to 75 minutes per shift, freeing up capacity for more picks without adding equipment. The gantry lifting speed of 5-15 m/min is similarly optimized for profile handling: slower lifting when retrieving delicate extrusions, faster lifting for structural steel angles.

High-Quality Component Architecture

Reliability is non-negotiable in automated storage. Herochu specifies only premium industrial components. The operator interface is a Siemens touchscreen, featuring a profile-specific menu where users can select stored profiles by series, alloy temper, length, and even remaining stock. Omron laser displacement sensors are mounted on the gantry’s gripper carriage to measure each profile’s exact position before picking; if a profile has shifted slightly due to previous retrievals, the sensors detect the offset and the gantry compensates. Schneider Electric motor starters and circuit protection devices ensure that electrical faults do not cascade through the system. The result is a mean time between failures (MTBF) exceeding 40,000 hours, even in facilities with ambient temperatures above 40°C.

Advanced WMS Features for Profile Management

The self-developed Warehouse Management System (WMS) from Herochu includes specialized modules for profile inventory. First, it supports “length tracking”: when a full-length profile (e.g., 6,000 mm) is partially consumed, the WMS can record the remaining length and assign that remnant to a new location. Second, the system implements “heat lot segregation,” preventing mixing of different batches when required by quality standards. Third, the WMS can generate “profile nesting suggestions” for downstream cutting operations, telling operators which stored profiles should be retrieved together to minimize offcuts. The Warehouse Control System (WCS) receives these retrieval commands and sequences the gantry’s movements to achieve the shortest possible path. Live inventory is displayed on large screens at the cutting station and loading dock, giving everyone real-time visibility.

Automatic Centering and Balance Management

Two features directly address common profile storage problems. The loading platform’s automatic centering function is invaluable for profiles that tend to roll or slide. When a bundle of profiles is placed on the platform, a series of pneumatic or electric pushers engages from both sides, squeezing the bundle until its centerline aligns with the gantry’s pick axis. This ensures that the gantry gripper engages the profiles symmetrically, preventing off-center lifting that could cause a fall. Balance management, meanwhile, monitors the weight on each shelf level. Profiles stored on upper levels create a higher tipping moment on the gantry column. Herochu’s balance management algorithm redistributes storage assignments automatically, keeping the center of gravity within safe limits. If an operator attempts to store an unusually heavy profile on a high shelf, the HMI will display a warning and suggest a lower location.

Technical Parameter Suite for Profile Storage

The Herochu automated gantry storage system for profiles is available in three core models. The HC-X6053-8 handles profile lengths up to 6,000 mm, with 5 layers (customizable), maximum load per level of 3,000 kg, and 8 racks (customizable). The HC-X7065-10 supports 7,000 mm profiles, 6 layers, 5,000 kg per level, and 10 racks. The HC-X8085-10 accommodates 8,000 mm profiles, 8 layers, 5,000 kg per level, and 10 racks. Gantry traveling speed is adjustable between 5 and 30 m/min; gantry lifting speed between 5 and 15 m/min. Repeatability is ±2 mm across all axes. These parameters are suitable for most aluminum extrusion warehouses, steel service centers, and architectural metal fabricators.

Integration with Existing Cutting and Sawing Lines

One of the most practical advantages of the Herochu Automated Gantry Storage System for Profiles is its ability to feed directly into downstream processing equipment. The WCS can be programmed to retrieve a specific profile, deliver it to an unloading station, and then signal the cutting saw to begin operation. For high-volume facilities, Herochu offers an optional conveyor extension that carries the profile from the gantry’s unloading platform directly into the saw’s infeed rollers. This turns the storage system into a just-in-time material supply for the entire production line. No intermediate staging, no manual handling, no risk of mixing profiles before cutting.

Real-World Installation: Architectural Aluminum Extruder

Consider a company extruding window and door profiles in lengths from 4,000 mm to 7,000 mm. They previously stored profiles in cantilever racks organized by series. Retrieval required a worker to locate the correct rack, pull out the profile, walk it to the saw, and manually record the removal. Errors were common, and inventory counts were always inaccurate. After installing a Herochu HC-X7065-10 automated gantry storage system, the extruder now scans each incoming bundle’s barcode; the gantry places it in a WMS-assigned location; retrieval is done by entering the order number on the Siemens touchscreen; and the system automatically updates inventory. The facility reduced its storage footprint by 60% because the gantry’s mobile shelves eliminated fixed aisles. The error rate for profile selection dropped from 8% to 0.2%. Worker injuries from lifting heavy profile bundles fell to zero.

Protective Sheet Metal and Safety Features

The external protective sheet metal on the Herochu system serves dual purposes. First, it contains any dust, chips, or lubricants that may shed from stored profiles, keeping the warehouse floor cleaner. Second, it prevents direct contact with the gantry’s high-speed moving parts. Integrated light curtains at each aisle entrance automatically cut power to the gantry if someone walks into the storage area while the system is active. Emergency stop buttons are located at both ends of the gantry travel and at the HMI station. For compliance with regional safety regulations, Herochu can supply CE or UL certification upon request.

Conclusion: A Purpose-Built Solution

Many storage vendors offer general-purpose gantries and expect customers to adapt their profile handling processes. Herochu takes the opposite approach: the Automated Gantry Storage System for Profiles was designed from the ground up for profiles. From the shape-specific cradles to the length-tracking WMS, every feature addresses a real challenge faced by profile handlers. For any company that wants to move beyond manual or semi-automated profile storage, Herochu provides a proven, high-speed, and reliable automated solution.