What Is a Pick Module?
A pick module is a multi-level structure that stacks picking on top of picking: pallet racking, carton flow, and shelving arranged across two or more levels, tied together by conveyor. It concentrates your fastest-moving SKUs into a compact, vertical engine where pickers walk steps instead of aisles.
A pick module is equal parts structure, storage, and flow design. Getting slotting and replenishment paths right is what separates a module that doubles pick rates from an expensive mezzanine with shelves on it.
What Goes Into a Pick Module
Carton flow levels
Gravity flow shelves presenting cartons at the pick face, replenished from behind without interrupting picking.
Pallet flow and selective levels
Full-pallet picking and reserve storage integrated into the same structure.
Shelving levels
Static shelving for slower movers and small items within the module.
Takeaway conveyor
Powered takeaway on each level feeding a spiral or incline to sortation and packing.
Structural platform
The engineered steel structure, stairs, gates, and fire protection that make it a building within a building.
Lighting and pick technology
Pick-to-light, put walls, and scanning integrated at the face.
How MTLI Works With Pick Module
Design & Engineering
It starts with your data, not a catalog: throughput, product profile, building, and budget. Our engineers design the right answer, with stamped drawings and permits where structures are involved.
Supply & Procurement
We source across 500+ manufacturer partners worldwide, brand-agnostic, new and used where it makes sense, with volume pricing passed through to you.
Installation & Commissioning
Our own crews install, integrate, and commission, phased around live operations when needed, with an MTLI supervisor on site every day and 98% on-time delivery.
Support & Lifecycle
After handover we stay: preventative maintenance programs, inspections, controls support, and 24/7 options, designed around your uptime targets.
Where MTLI Can Help You
- High-velocity SKU concentration for case and each picking
- Adding picking capacity without expanding the building
- New fulfillment center design around waveless picking
- Retrofitting modules over live operations in phases
- Multi-site rollout programs with repeatable module designs
- Full structural engineering, permits, and installation as one scope
From under $100K to $100M+ turnkey. A specialist calls within one business day.
Common Questions, Answered
How much does a pick module increase pick rates?
Well-designed modules routinely double or triple picks per hour versus aisle picking, because travel collapses to steps and product presents at ergonomic height.
Does a pick module need permits?
Yes, it is a structure with egress, rail, and fire-protection requirements. MTLI delivers stamped engineering and manages permits and inspections end to end.
Can you build a module over a live floor?
Yes, phased structural work on off-shifts is standard for us, including programs across 24+ facilities in six months.
Who supplies the racking and flow beds?
MTLI sources across 500+ manufacturer partners worldwide, new and used, so the module is engineered to your SKUs rather than one catalog.