Dexion Tornado Automated Vertical Storage Machine

Dexion Tornado automated vertical storage machine for demanding warehouses

When your warehouse runs on small parts, every extra step shows up in lead times. Walking the aisles, searching shelf locations and double-checking picks costs time. It also increases the risk of errors. The Dexion Tornado vertical lift module (VLM) is built to take that waste out of daily work by bringing the right tray to the operator, exactly when it is needed.

Tornado is a lift-based warehouse automation solution and one of the most widely used vertical lift storage systems in Finland. Inside the unit, an integrated lift retrieves trays (also referred to as levels) and delivers them to the access opening. The system automatically supports efficient storage and a logical picking sequence, so the operator can focus on picking and replenishment instead of moving around the warehouse. Tornado is designed and manufactured in Finland.

How the Tornado vertical lift module works

The Tornado vertical lift module stores trays vertically inside the machine. When an item is requested, the internal lift travels to the correct tray position, retrieves the tray and presents it at the access opening at a comfortable working height. Once the pick is completed, the tray is returned and the next tray is delivered. Because the system moves vertically and stores trays close together, it concentrates a large amount of stock in a small footprint.

In practice, this means the operator stays in one working area. Instead of spending time walking to shelves, the VLM delivers the required items to the access opening. This “goods-to-person” approach can improve picking speed by up to 65% compared with traditional manual storage methods, depending on your pick profiles, batch size and operating model.

Use height to save floor space

Floor space is expensive, and aisle space is often the hidden cost of conventional shelving. The Tornado automated vertical storage machine is designed to make full use of available ceiling height while keeping the footprint compact. In many cases, this approach can save up to 75% of floor space compared with standard shelf storage, because you no longer need long access aisles for every shelf row.

That saved space can be used for packing stations, value-adding work, or simply for keeping traffic lanes clear. For facilities that are already at capacity, vertical storage is also a practical way to increase storage density without moving to a larger building.

Productivity for small parts picking

Tornado is suitable for environments where speed and repeatability matter, such as industrial plants, distribution centres and retail back-of-house storage. The system can store hundreds of different items at the same time and still provide fast access to each one. By reducing walking and searching, the operator can process more order lines per hour with less fatigue.

The Tornado vertical lift module can be configured for high throughput. With the right configuration and workflow, it can handle up to 1,500 bins per hour. This makes it a strong option not only for today’s volumes, but also for operations that expect growth and want a storage system that can keep up.

Accuracy and flexibility when the assortment changes

Fast picking is only valuable when it is accurate. With a controlled, tray-based workflow and clear system guidance, picking accuracy can reach up to 99.9%. This helps reduce rework and time spent on corrections. It is useful wherever the wrong item causes delays, from production parts to retail replenishment.

Tray layouts can be adjusted to match your product mix. The storage positions can be configured for different item sizes and weights, which is helpful when the assortment changes over time or includes mixed-size parts. This flexibility also supports orderly replenishment: items can be grouped logically to match your pick frequency, and you can update the organisation as demand changes.

Integration with your WMS or ERP

Tornado supports modern warehouse management routines, including real-time visibility of stock levels. By integrating the system with other warehouse solutions or with your ERP, you can follow inventory status continuously and keep ordering and replenishment decisions up to date.

The user interface is Windows-based and built for daily warehouse use. The combination of the TC1200 control system and the optional TCPlus WMS supports paperless order processing, reducing manual paper handling and helping to keep picking consistent across shifts.

Configuration, sizing and installation options

The Tornado automated vertical storage machine can be sized for different buildings and workflows. The unit is available in multiple dimensions, and it can also be installed in special ways when the site demands it. If needed, the system can even be built through a wall, with the unit body located outside the building. This can be useful when indoor space is limited or when you want to free up premium production and packing areas.

For multi-storey facilities, it is possible to create multiple access openings on different floors. This allows the same Tornado VLM to serve more than one work area, improving overall efficiency and reducing internal transport between floors.

Quiet, computer-controlled and energy efficient

Because the system is computer-controlled and designed for continuous use, Tornado offers stable, repeatable performance in daily operation. The system is described as quiet, which supports a more comfortable working environment near picking and assembly areas. Tornado is also energy saving, making it a sensible choice when the unit runs intensively for many hours per day.

Ergonomics and safety built into daily work

Tornado is designed to improve picking ergonomics. Trays are presented to the operator automatically, which reduces unnecessary lifting, reaching and walking. A clear user interface helps operators complete daily picking and replenishment tasks efficiently.

Safety features are designed to protect the operator from moving parts. Light curtains and sensors help ensure that the access opening remains safe during operation. The system stops immediately if the light curtain is interrupted or if sensors detect unexpected movement. Emergency-stop buttons are placed within easy reach so the process can be stopped instantly when needed.

Technical data

• Power supply: 400 V / 16 A
• Overall dimensions (W × H × D): width 2500–4250 mm, height 4000–15,000 mm, depth 2100–4200 mm
• Tray load options: 300 kg, 400 kg or 500 kg (choose based on your products)

Accessories and expansion options

You can improve throughput and usability further with optional accessories. The best combination depends on your item identification needs and the level of picking guidance you want at the station.

• Light pointer: indicates the correct pick position on the tray to speed up picking.
• Infeed shelf and barcode scanner: supports replenishment and reliable item identification.
• Label printer and touchscreen: reduces paperwork and makes control faster at the station.
• IP camera: enables remote support or monitoring.
• Plexiglass end panels: add protection from dust and bumps and improve safety.
• Conveyors and roller tracks: connect the VLM to packing or production flow for smoother material transfer.

Request a quote and planning support

If you want to know what size and configuration fits your site, ask for details and planning support. Contact us for more information and a quotation: myynti@thtt.fi or call +358 2 431 0400 (Mon–Fri 8:00–16:00).