Warehouse automation in the metalworking industry has moved beyond conveyor systems and robotic picking arms. For steel service centers and metal fabrication workshops, the storage of steel plates, aluminum sheets, and iron plates represents one of the last manually intensive operations on the shop floor. The Herochu vertical steel plate storage system brings automated retrieval, real-time inventory tracking, and ERP-linked material management to this workflow — turning a passive storage area into an active component of the factory data network.
From Manual Racks to Automated Vertical Storage
Conventional sheet metal storage relies on horizontal racks, A-frames, or stacked pallets positioned across the workshop floor. Retrieving a specific plate requires a forklift operator to locate the sheet, navigate narrow aisles, extract it from a stack without damaging adjacent plates, and transport it to the processing area. This process is slow, labor-intensive, and prone to material mix-ups.
The Herochu vertical storage system replaces this model with a single-tower arrangement that stores the complete sheet metal stock in one compact vertical column. Plates are loaded into individual trays, separated by steel layers, and retrieved through an automated lifting mechanism controlled via PLC touchscreen. The operator selects the required sheet by size, thickness, or batch number, and the tower delivers it to the access opening — no forklift navigation, no manual searching, no risk of surface damage from stacking.
Technical Specifications Across the Model Range
Herochu manufactures four standard models designed for different sheet dimensions and load capacities:
- HC-S3015-63: Handles 3000×1500 mm sheets across 6 customizable layers, with a maximum load of 3000 kg per level
- HC-S4015-85: Accommodates 4000×1500 mm sheets across 8 customizable layers, rated for 5000 kg per level
- HC-S4020-85: Stores 4000×2000 mm sheets across 8 customizable layers, supporting 5000 kg per level
- HC-S6020-105: Handles 6000×2000 mm sheets across 10 customizable layers, with 5000 kg capacity per level
Clear space between trays defaults to 350 mm and is customizable for facilities storing thicker plates or mixed material profiles. The transfer speed for entry-exit and lifting operations ranges from 5 to 15 m/min, with a repeatability of ±2 mm — specifications that ensure reliable tray positioning under continuous production loads.
PLC Classification and One-Key Retrieval
At the center of the Herochu system is a PLC touchscreen controller that manages sheet classification, storage positioning, and retrieval sequencing. When material arrives at the inbound station, the controller registers the plate dimensions and weight, then assigns it to the appropriate layer and slot within the tower. Automatic positioning locates the exact storage position for every sheet, removing operator judgment from the placement process.
Retrieval follows the same automated logic. The operator enters the required sheet specification, and the system retrieves the matching tray. One-key delivery brings the designated plate directly to the operator, accelerating production preparation and reducing the idle time that accumulates when operators wait for manual material retrieval.
Real-Time Inventory and Weight Monitoring
The Herochu vertical storage system maintains a real-time digital inventory of every stored sheet. The control screen displays material dimensions, weight, and quantity, updated continuously as sheets enter and exit the tower. A built-in weighing function records the weight of each stored plate, providing accurate stock records that support both inventory accounting and material traceability.
This real-time visibility eliminates the need for periodic manual stock counts. Steel service centers that previously dedicated labor hours to weekly or monthly physical inventory can now generate accurate stock reports on demand — the system maintains the data set and updates it with every storage transaction.
ERP and WMS Data Integration
The storage tower connects to factory ERP and WMS systems through standard data interfaces, supporting several warehouse automation functions:
Material Planning: Production schedules reference real-time stock data to confirm material availability before releasing a job to the floor. This prevents production starts that stall due to missing or misidentified stock.
Batch Traceability: Every metal sheet is tracked from inbound storage to outbound loading. The system records which batch a sheet belongs to, when it entered storage, and when it was retrieved — supporting quality control, order verification, and compliance documentation.
Expiration Warnings: Sheets that exceed a configured storage period are flagged automatically. This prevents aged stock from entering production unnoticed, a risk that matters when material properties degrade over extended storage periods.
Data Consistency: The tower and factory ERP share a single data set. When a sheet is retrieved, the ERP system reflects the stock reduction in real time — no manual data entry, no end-of-shift reconciliation, no discrepancies between physical stock and system records.
Structural Design and Workshop Compatibility
The Herochu vertical storage system is built on a rigid steel frame designed for continuous automated sheet handling. A powder-coated surface provides anti-rust performance across every steel layer, while ESD protection adds static discharge safety for aluminum sheet storage. Loading and unloading stations are compatible with forklifts, overhead cranes, and standard lifting equipment, with adjustable conveyor legs and leveling feet that accommodate existing floor conditions.
Layer count, tower quantity, tray size, load capacity, and net clearance are customizable to match each facility’s layout, plate dimensions, and production volume. The system is engineered for steel service centers, metal fabrication workshops, steel distributors, and aluminum extrusion processors — operations where warehouse automation means more than conveyors and robots, extending into the intelligent management of sheet metal stock from inbound receiving through to production-ready retrieval.
