Warehouse operations across the UK are under increasing pressure to process more products, fulfil orders more quickly, and maintain consistently high levels of accuracy. As workloads grow, so does the potential for workplace injuries, particularly in facilities that still depend on manual storage and picking methods.
A vertical lift module (VLM) helps create a safer, more ergonomic working environment by bringing stored items directly to the operator. This reduces unnecessary lifting, bending, stretching, and climbing while improving overall efficiency. This guide explains how VLMs contribute to warehouse safety and outlines practical ways to support a healthier workplace.
Manual picking involves employees frequently performing repetitive movements, reaching into awkward spaces, lifting heavy items, and walking long distances during a shift, all of which can contribute to musculoskeletal disorders (MSDs). According to the Health and Safety Executive, manual handling continues to be one of the leading causes of workplace injuries in Great Britain.
As businesses expand their product ranges and increase order volumes, traditional shelving systems can place additional physical demands on warehouse teams. Beyond the personal impact on employees, injuries may lead to lost productivity, operational delays, and increased costs. Investing in ergonomic storage solutions is one way organisations can help reduce these risks.
A VLM is an automated storage and retrieval system designed to deliver items directly to a convenient picking position. Rather than travelling through warehouse aisles or accessing high and low shelving, operators remain at a single workstation while the system automatically presents the required tray.
By supporting a goods-to-person workflow, VLMs help reduce physical strain and create a more controlled picking process.
A VLM, such as the Kardex Shuttle Vertical Lift Module, can help organisations:
For businesses seeking to modernise warehouse operations, VLMs provide a practical way to improve both safety and storage efficiency.
Safety light curtains monitor the access opening and immediately stop tray movement if an object or person enters the protected area. This helps reduce the risk of accidental contact during operation.
Shutter doors remain closed while trays travel inside the machine, preventing access to moving components and helping keep dust and debris away from the operator.
The tray presentation height can be adapted to suit different operators, allowing goods to be picked within a comfortable working range and reducing repetitive strain caused by reaching or bending.
Inventory is stored securely inside the enclosed unit, reducing the chance of falling items while helping to control access to valuable or sensitive products.
Tray movement can be adjusted to suit the stored inventory. Standard items may be presented at normal speed, while fragile or delicate products can be handled more carefully through reduced-speed operation.
For oversized or difficult-to-handle products, trays can be manually extended to adjacent workstations or carts, providing greater flexibility while maintaining safe handling practices.
Integrated sensors monitor tray weight and prevent operation if safe load limits are exceeded, helping protect both the equipment and operators.
Clearly positioned emergency stop buttons allow operators to halt machine movement instantly. Lockout functions provide an additional level of protection during servicing and maintenance.
Optional fire protection systems, including aspirating smoke detection and inert gas suppression, offer additional protection for valuable inventory and facilities storing regulated or sensitive materials.
Even with advanced automation, safe warehouse operations depend on effective procedures and employee training. Consider the following best practices:
A UK manufacturer handling heavy equipment parts faced frequent strain injuries due to manual lifting and long picking routes. After installing two VLMs equipped with ergonomic hoists and controlled tray extraction, the company:
This example demonstrates how automated vertical storage can improve workplace safety while simultaneously increasing operational efficiency.
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Kardex Automated Storage & Retrieval Solutions