ASRS vs. AMRs: How the Robotic Solutions Differ, and Where They Can Collaborate

In the fast-evolving world of warehouse automation, the number of acronyms and robotic technologies can feel overwhelming—even for seasoned logistics professionals. In this episode of Hai-er Automation, host Michelle Dawn Mooney sits down with Jake Etheridge, Technical Sales Executive at Hai Robotics USA, to break down one of the most common areas of confusion: the differences and real-world applications of ASRS (Automated Storage and Retrieval Systems) and AMRs (Autonomous Mobile Robots).

While both ASRS and AMRs fall under the broader category of warehouse robotics and play critical roles in modern warehouse automation solutions, they differ significantly in design, operation, scalability, and the problems they’re built to solve. Understanding these distinctions is key for distribution centers, e-commerce operations, 3PLs, and manufacturers looking to improve warehouse efficiency.

Jake walks through these differences in detail and also highlights why many of the most successful facilities today are leveraging ASRS–AMR hybrid workflows—a strategy that leading warehouse automation system integrators increasingly recommend.

Shared Benefits and Environmental Constraints: Where ASRS and AMRs Overlap

Before diving into the differences, Jake emphasizes that both technologies share several similarities that often confuse first-time buyers:

Both ASRS and AMRs:

• Improve order picking efficiency and streamline workflows

• Require infrastructure checks such as floor flatness and environmental suitability

• Cannot operate in certain harsh environments (example: AMRs often struggle in freezers due to sensor condensation)

• Act as components of a broader warehouse systems integration strategy rather than complete end-to-end solutions

In practice, ASRS and AMRs rarely replace an entire workflow on their own. Instead, they function as part of a connected ecosystem involving WMS/WCS software, conveyors, packing stations, and more.

This is why working with experienced warehouse automation system integrators is essential—especially for businesses new to automation.

ASRS: High-Density, Fully Automated Storage for Maximum Space and Throughput

Unlike flexible AMRs, ASRS systems are enclosed, high-density storage solutions designed to automate product retrieval with little or no human interaction inside the storage area.

Defining Characteristics of ASRS

• Operates in a fixed, enclosed footprint

• Keeps humans out of the storage zone for safety and efficiency

• Uses robots or shuttles with pre-defined travel paths

• Supports extremely high vertical storage (often 12m / ~40 ft)

• Greatly increases storage density due to narrow aisles and no human access requirements

Traditionally, ASRS systems were crane-based—but today's shuttle-based and multi-robot systems allow for:

• aisle changing,

• multi-directional travel,

• higher throughput capabilities.

Where ASRS excels in warehouse automation

• Freezer environments: eliminates the need for employees to work in -20°C spaces

• High-volume order picking: maximizes throughput with minimal touchpoints

• High-value goods: improves product security by restricting physical access

• Operations lacking space: increases storage capacity without warehouse expansion

Limitations

• Longer design and deployment cycles

• Less flexible for irregular or oversized items

• Requires validation that SKUs fit in totes or standardized storage bins

In other words, ASRS is ideal for facilities that need maximum efficiency, dense storage, and predictable workflows—often seen in e-commerce, retail replenishment, and 3PL automation.

AMRs: Flexible, Human-Assisted Robots for Fast Deployment and Adaptability

In contrast, Autonomous Mobile Robots (AMRs) are designed for flexibility and dynamic movement inside human workspaces. They require minimal infrastructure changes and can be deployed within weeks rather than months.

Key Benefits of AMRs in Warehouse Robotics

• Freely navigate floors using SLAM or LiDAR

• Work alongside people—ideal for cart-based or manual picking systems

• Handle a broad range of tasks:

  • tote transport

  • replenishment

  • long-item movements (e.g., 20-ft pipes)

  • WIP movement in manufacturing

• Highly scalable and cost-effective

• Best choice when SKU sizes are irregular or not ASRS-friendly

Some AMRs even follow human pickers or meet them at the next assignment location—reducing walking time and improving ergonomics.

Why AMRs?

They shine in operations requiring adaptability, especially in:

• Multi-SKU, high-mix warehouses

• Fast-changing 3PL environments

• Manufacturers needing automated WIP movement

• Operations needing quick automation wins

ASRS vs. AMRs: Choosing the Right Warehouse Automation Solution

Jake shares a simple framework to help businesses decide:

Choose ASRS if your goals include:

• Maximizing space utilization

• Increasing throughput with minimal human touchpoints

• Improving product security

• Scaling efficiently within existing square footage

• Eliminating walking in picking processes

Choose AMRs if you need:

• Flexibility

• Fast deployment (1–2 months)

• Support for irregular product sizes

• Automation that coexists with manual workflows

• A scalable, cost-effective starting point

Real-World Integration: When ASRS and AMRs Combine for Maximum Efficiency

Some of the most advanced warehouses today use ASRS + AMRs together—and the Podcast provides a powerful example.

Case Example: ASRS + AMR Hybrid Workflow

• ASRS robots retrieve totes or pallets from high-density storage

• They deliver items to a human at a pick station

• The worker builds outbound orders onto a pallet

• AMRs then take over, transporting the full pallet

  • to staging

  • to conveyors

  • to an automated pallet wrapper

  • and finally to outbound lanes

• Forklift drivers only need to load pallets onto trucks

This approach automates nearly the entire picking and shipping process—without forcing humans to perform long walks or operate in restricted spaces.

This type of hybrid solution reflects what modern warehouse automation system integrators increasingly recommend: combining the dense storage of ASRS with the mobility and flexibility of AMRs.

Advice for Businesses Considering Automation

Jake closes the episode with straightforward advice:

• Start by understanding your workflows, SKU profile, and long-term goals

• Talk to an experienced warehouse automation integrator early

• Explore both ASRS and AMRs, even if you think you already prefer one

• Expect automation to become increasingly affordable and accessible

Automation is no longer only for mega-warehouses—mid-sized warehouses, regional 3PLs, and specialty distributors are now some of the fastest adopters due to decreasing entry barriers and rapid ROI.

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Find out whether an ASRS or AMR solution is best for your application with our free side-by-side comparison: