Paternoster

The paternoster is a remarkable technical innovation that has developed from a classic passenger lift into a highly efficient storage system. Its characteristic continuous circulation initially revolutionised passenger transport in administrative buildings in the post-war period.

The original concept, named after the arrangement of the cabins reminiscent of a rosary, proved its versatility through the successful transformation into a modern circulating storage system. This further development opened up new perspectives for intralogistics, especially in the area of small parts storage.

Today, the paternoster storage system combines proven mechanical principles with digital control technology, enabling a highly efficient, space-saving and ergonomic storage solution for a wide range of industries and applications.

What is a paternoster? History and etymology

The paternoster is defined as a continuously moving transport system whose history goes back to the late 19th century. Its name comes from the Latin ‘Pater Noster’ (Our Father), as the circulating cabins are reminiscent of the beads of a rosary. Miners were largely responsible for coining this term through their daily use of the lift systems underground.

The classic passenger lift became a symbol of modern administrative buildings, particularly in the post-war period. Equipped with two parallel shafts, the system enabled uninterrupted passenger transport. The characteristic cabins each offered space for two people and moved up and down in an endless cycle.

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The concept was revolutionary in that it eliminated waiting times. Users could board and alight spontaneously, while the cabins moved at a constant speed. This efficiency led to the widespread use of the system in public facilities, making the paternoster a permanent part of the building infrastructure.

The paternoster principle: how it works in detail

The paternoster principle is based on a well-thought-out mechanical system of continuous movement. The central components are two parallel shafts in which cabins permanently circulate on robust steel chains. At the turning points, the direction of travel is changed by means of special deflection devices that ensure a smooth transition.

The drive technology uses an electric motor that ensures the smooth movement of all cabins. Counterweights provide stability and energy-efficient operation. Precise control mechanisms permanently monitor the movements and guarantee the operational reliability of the system.

The operating principle enables maximum transport efficiency through constant availability. Unlike conventional lifts, the paternoster knows no waiting times. The even speed allows safe entry and exit during operation. Sensors permanently monitor the correct position and movement of the cabins.

How does a paternoster work? Technical basics

The technical functioning of a paternoster is based on sophisticated mechanics and modern control technology. The drive system consists of a powerful electric motor that controls the movement of the cabin chain via gears and power transmission elements. Precise guide rails ensure the exact positioning of the individual transport units.

Safety systems play a central role in the operation. Multiple redundant sensors continuously monitor the movements and position of each cabin. In case of irregularities, the system is shut down immediately. Modern control units process the sensor data in real time and permanently optimise the movement sequence.

The turning points are particularly technically demanding areas. Special deflection devices ensure that the cabins change direction smoothly. The precise coordination of all mechanical components enables the system’s characteristic continuous operation. Maintenance-friendliness and durability characterise the technical design of all components.

From personnel transport to the paternoster storage system

The further development of the classic personnel paternoster into a modern storage system marks a significant advance in intralogistics. By adapting the original transport cabins, specialised storage compartments have been created that are ideally suited for storing a wide range of materials. This transformation has made it possible to significantly increase storage capacity while simultaneously minimising the floor space required.

The paternoster storage system uses the proven circulation principle for efficient material supply. The continuous movement of the storage compartments allows employees to quickly and ergonomically access the items they need. Converting existing paternoster systems into modern storage facilities proves the adaptability of the basic concept to new requirements.

The integration of digital control technology also optimises warehouse management. Modern paternoster storage systems are equipped with precise positioning systems and electronic inventory management. These technical upgrades increase the efficiency of material flow and significantly reduce search times.

Modern paternoster storage systems in practice

Paternoster storage systems are particularly useful for storing small parts and medium-sized components. The variable compartment sizes allow for flexible adaptation to different storage goods. Sensitive materials benefit from the closed system, which offers optimal protection against environmental influences.

The vertical design of the paternoster storage system makes optimal use of the available room height. This efficient use of space allows large storage capacities to be realised on a minimal floor area. The compact design also enables short access times and significantly reduces the distances that employees have to walk.

Modern control systems support the picking process with intelligent functions. Pick-by-light systems or digital display units guide employees accurately to the desired items. These technical aids increase picking accuracy and speed up the picking process.

Advantages of the carousel storage system

The carousel storage system offers significant advantages over conventional storage facilities. The compact design reduces the space required by up to 70 per cent compared to static shelving systems. This space saving allows for optimal utilisation of existing building structures and significantly reduces occupancy costs.

The ergonomic design of the picking positions minimises physical strain. Storage compartments automatically move to the optimum working height, allowing employees to pick items without bending or stretching. This ergonomic workplace design reduces health risks and increases employee satisfaction.

Automated material provision significantly reduces access times. While they are waiting, employees can already prepare the next picking orders. This process optimisation increases work efficiency and reduces unproductive non-productive times.

Increased efficiency through the paternoster warehouse

A modern paternoster warehouse increases operational efficiency by systematically optimising processes. The integration of digital warehouse management systems enables precise inventory management in real time. Automatic reordering when stocks fall below defined minimum levels prevents material bottlenecks and optimises the capital tie-up.

The structured arrangement of the storage compartments significantly simplifies the search for items. Digital position indicators guide employees directly to the desired storage compartment. This targeted navigation reduces search times and minimises the risk of incorrect picks. In addition, the systematic arrangement of items enables demand-oriented zoning of the storage area.

The paternoster principle supports the implementation of various picking strategies. Multi-order picking or sequential picking can be efficiently realised. The permanent availability of all storage positions allows parallel picking processes without employees getting in each other’s way.

Fields of application for the paternoster system

Paternoster storage systems are used in a variety of ways in different industries. The system has proven particularly useful in the storage of small parts for production companies. The clear storage of tools, spare parts or components guarantees quick access during maintenance work or machine retooling.

The pharmaceutical industry uses paternoster systems for the safe storage of temperature-sensitive products. Closed systems protect medications from environmental influences and ensure constant storage conditions. The seamless documentation of all stock movements also fulfils regulatory requirements.

In retail, paternoster storage systems enable space-saving storage of goods. The quick availability of goods reduces refill times and optimises the presentation of goods on the sales floor. Seasonal fluctuations can be easily compensated for by flexible shelf division.

Special solutions and customisation of paternoster storage systems

The adaptability of the paternoster storage system allows for customised solutions for specific requirements. Variable compartment sizes and modular construction allow for optimal coordination with different storage goods. Special compartment fixtures protect sensitive materials from damage during movement.

Additional safety features significantly expand the range of applications. Access controls and documented removals ensure the safe storage of valuable goods. Climate-controlled versions create ideal storage conditions for temperature-sensitive products. The integration of fire protection systems increases operational safety.

Combining several paternoster systems into storage zones increases overall capacity. Intelligent control systems coordinate the movements of the individual systems and optimise the material flow. This networking enables efficient picking strategies, even for complex storage requirements.

Sustainability and energy efficiency

Modern paternoster storage systems set the standard in terms of sustainability. Energy-efficient drives and optimised control technology minimise power consumption. Load-dependent speed control automatically adjusts the speed of movement to the current transport volume.

The compact design not only reduces the space required, but also the energy required for air conditioning and lighting. LED technology and demand-controlled lighting systems further reduce power consumption. The long service life of all components reduces the consumption of resources for maintenance and spare parts.

The integration of renewable energies further improves the environmental balance. Photovoltaic systems on building roofs provide environmentally friendly electricity for the operation of the storage systems. Intelligent energy management optimises the use of available energy resources and reduces peak loads.

Conclusion: The paternoster storage system as a future-oriented concept

The paternoster storage system is continuously evolving and proves its sustainability through innovative technologies. The combination of proven mechanics and modern control technology creates efficient storage solutions for a wide range of requirements. Digitalisation and automation optimise processes and increase efficiency.

The integration of new technologies is constantly expanding the range of applications. Artificial intelligence and predictive analyses improve system efficiency. Autonomous transport systems and intelligent assistance functions support employees in their daily work. These technical innovations ensure the competitiveness of the storage system.

The focus on sustainability and energy efficiency makes the carousel storage system a future-oriented solution for modern intralogistics. The resource-saving design and innovative energy concepts meet current environmental requirements. This consistent further development ensures the long-term significance of the paternoster system in warehouse technology.

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