Development of a Multi-Layer Bi-Directional Gravity Conveyor Based Storage System for Continuous Storage and Retrieval of Bins in Buffer Zones

Abstract

Optimizing space utilization in manufacturing plants is crucial for enhancing production throughput, particularly in buffer storage zones where products must be temporarily stored between processes operating at different rates. Conventional single layer storage methods are often unable to accommodate fluctuating production outputs leading to bin overflow and inefficient use of available space. This paper presents the development of a multi-layer bi-directional gravity conveyor–based storage system designed to maximize buffer zone capacity within a compact foot print. The proposed system integrates three levels of gravity flow beds with a com pact vertical conveyor for continuous movement of bins between levels, eliminating the need for forklifts for loads up to 100 kg. The system was designed to occupy a floor space of 7 m × 3 m × 6.5 m and achieve a maximum storage capacity of 6 tons. Finite element analysis (FEM) was used to verify structural reliability, confirming stresses and deflections within safe operating limits. Compared to conventional single-level storage, the proposed system achieves up to three times higher storage density. The design ensures a scalable and energy efficient storage system with high throughput.