The Escala consists of just 15 structural steel components and the 3D shuttles as the only automated component. To change levels in the storage cube, the 3D shuttles use ramps instead of lifts.

The Escala is divided into two areas: the ramp towers, which allow the 3D shuttles to change levels, and the storage areas, where containers are stored. The basic principle is based on a parking garage. Due to the one-way traffic in the ramps and the possibility of reaching every point in the storage cube via different routes, the Escala competes with the performance of a single-level shuttle, but with significantly better scalability and higher redundancy.

Performance indicators include the number of ramp towers next to each other, whereby the width of the system should correspond to the height in order to achieve the best possible performance utilization. By linking several ramp towers next to each other, it is possible to travel over several levels without changing direction, which increases the performance of each 3D shuttle. On the other hand, the configuration of the storage areas is crucial: the storage areas can be designed to be one to six times deep at any level. This makes it possible to create fast-moving and slow-moving or replenishment areas within the same system.

The Escala from Movu Germany took first place in the Order Picking Technology category in the Product of the Year 2024. © WBM

In a single-depth configuration, the 3D shuttle can remove the required container directly. In a multi-deep configuration, the required container may have to be "dug out". As a high degree of compaction of the stored goods is possible with multi-deep storage, a combination of both areas usually makes sense in order to achieve a good performance and compaction ratio on the one hand and to ensure sufficient flexibility for changes to the ABC curve in the long term. Compared to other 3D AS/RS, a free combination of multi-deep and single-deep storage areas is possible. This makes it possible to map a wide variety of ABC profiles and leads to a high degree of flexibility when changing the ABC profile.

It also enables functions such as order buffering and one hundred percent sequencing to be carried out without changing the hardware. The decoupling of storage location and container means that different container heights can be mixed as required and changed at any time. Lower containers are stacked on top of each other and stored together in a storage compartment. On the way to the workstation, the required container is "turned" upwards by a re-stacker. This enables, for example, the use of 120 millimetre high containers with a significantly higher subdivision than with 320 millimetre high containers.

The Escala therefore achieves better compaction than cubic AS/RS solutions for small SKUs with low quantities. Compared to other 3D AS/RSs, the Escala uses standard containers from any manufacturer in two basic sizes - 600 x 400 or 650 x 450 millimeters and can carry weights of up to 50 kilograms. The container holder allows existing storage containers to be used as long as they have a reinforced base. This means that the existing container pool can be used, resulting in process-related benefits and significant cost reductions. The high level of standardization greatly reduces the planning effort in the project and all components can be produced in large quantities. This leads to a reduction in costs and enables full automation from 250,000 euros. Depending on the ratio of output to storage space, Escala achieves a return on investment of two to three years.