How a Load Bank Manufacturing Unit Optimised Storage Space with 4 Rabatex VLMs
Meload Works, a 100% export-oriented manufacturer of load banks and power test equipment in Anand, Gujarat, installed four Rabatex Rapid Vertical Lift Modules (VLMs) in its new facility. The VLMs store the components, parts and tools used in load bank manufacturing in a compact vertical footprint and bring the required tray to the operator, so people no longer walk and search through racks.
Meload Works Vertical Lift Module Project at a Glance
Customer
Meload Works, a 100% export-oriented unit
Location
Vallabh Vidyanagar, Anand, Gujarat, India
Industry
Electrical equipment manufacturing (load banks)
Solution
Rabatex Rapid VLM, 4 units with double access
Installed
2024, new facility
About Meload Works
Meload Works is a 100% export-oriented manufacturer of load banks and power test equipment based in Vallabh Vidyanagar, Anand, Gujarat, India. The company specialises in designing and manufacturing equipment used to test, measure and validate electrical power systems.
Its product range includes stationary and trailer-mounted load banks in the 1 MW to 3 MW range, with 480 V and 1500 VDC variants, along with power test accessories. These solutions help customers test generators and power systems under different operating conditions.
With a focus on customised, engineering-led solutions, Meload Works caters to specific power testing requirements across applications. The company also emphasises long-term customer support, helping businesses maintain reliable power systems and minimise disruptions to their energy supply.
What Storage Challenges Did This Load Bank Manufacturer Face?
Load bank manufacturing needs many small and medium-sized components, such as connectors, sensors, fasteners and cables, on hand whenever the assembly line needs them. In its earlier facility, Meload Works stored these on conventional racks and shelving and ran the operation manually. That caused three problems.
1
Inventory storage took a large floor area.
2
Operators spent considerable time searching for parts. Store management also required skilled workers, making the operation manpower-dependent and increasing the cost per pick/item.
3
Manual, manpower-dependent stock management created discrepancies between virtual stock and physically available stock, with limited traceability and user management.
When the new facility was planned, management chose automated vertical storage for its floor space saving, manpower saving, real-time inventory data and ERP integration.
What Was the Solution?
Four Rabatex Rapid Vertical Lift Modules
Rabatex supplied four Rapid VLMs, designed and manufactured in-house at its Ahmedabad facility. A VLM stores items on trays inside a compact vertical enclosure and brings the required tray to the operator at an access window.
Touch-screen HMI
Height sensors that make full use of tray space
Weight sensors that alert the operator if a tray is overloaded
Barcode-identified trays with indigenous software for multilevel inventory tracking
Option to integrate with ERP systems such as SAP
- Access point 1
Ground floor
For inward inventory
- Access point 1
Ground floor
For inward inventory
The machine height and tray height were set to suit the height available in the space. Each of the four VLMs has double access. The first is on the ground floor for inward inventory. The second is at a 6-meter-high assembly area, where parts are removed for production.
How Did the Rapid VLM Solve Each Storage Problem?
| Challenge | Result with Rabatex’s Rapid VLM |
|---|---|
| Large floor area for racks | Items are stored vertically, using available height to increase storage capacity and saving approximately 85% of floor space. |
| Walking and searching for parts | Trays are delivered to the operator at the access window, reducing the number of operators required to manage the store and lowering the cost per pick. |
| Stock accuracy depending on manual records | Barcode-identified trays and software tracking keep stock records accurate and traceable, with real-time data and ERP integration available. |
How Was the Vertical Lift Module Installed?
Rabatex manufactured the four vertical lift modules at its Ahmedabad facility and delivered them to Meload Works in Anand. Once each VLM was unloaded at the site, the Rabatex service team began installation, which took roughly 15 to 17 days per VLM. After installation, the team demonstrated the system, ran trials and trained the operators so the Meload Works team knew how to use it.
- Machine manufacturing
- Installation
- Commissioning
- Testing and trials
- Operator training
- Technical support
- After-sales support
- After-sales support
How Rabatex Vertical Lift Module Helped Meload Works
Meload Works now runs its production storage on 4 Rapid VLMs, each with 2 access points, instead of conventional racks and shelving.
4
2
6 m
15–17
2024
Vertical storage frees floor area for production, trays reach the operator at the access window, and barcode-identified trays keep stock records traceable.
Meload Works Now Stores Its Production Parts Vertically, Not Across the Floor
The Meload Works project shows what a vertical lift module can do for a manufacturer whose parts have outgrown its racks. Its four Rapid VLMs give the team an automated storage system planned around its own building, with parts delivered to the operator, stock records that stay traceable and floor space left for production.
At Rabatex, we build our machines with key components from Japanese and European brands, so they perform well and the parts last. We also stay involved after installation. Our service team supports every machine we supply, and during demonstration and training, we explain to your team how the machine works and what output to expect from it.
If you are setting up a new facility or expanding your current premises, we can help you plan a vertical lift module around the height and space you have.
Need a Vertical Lift Module for Your Facility? Talk to Rabatex
If your facility is short on floor space or loses time searching for parts, share your available height and the items you store with the Rabatex team.
Four Rabatex Rapid Vertical Lift Modules
What is a vertical lift module and how does it work?
A vertical lift module (VLM) is an automated storage machine with trays stacked inside a vertical enclosure. When an item is needed, the machine brings the tray that holds it to the access window, so the operator picks the item without walking through racks.
How does a VLM save floor space compared with racks?
A VLM stores items on trays stacked vertically, so it uses the height of your building instead of floor area. Racks and shelving spread items across the floor and need space to walk between them. How much floor space you save depends on the height available and the items you store. Meload Works chose VLMs to keep more of its floor free for production.
Can a VLM store small parts like connectors, sensors and fasteners?
Yes. Meload Works uses its VLMs for small and medium-sized components such as electrical parts, connectors, sensors, fasteners and cables, along with tools. Height sensors help make full use of the space on each tray, and weight sensors alert the operator if a tray is overloaded.
Can a VLM fit the ceiling height of my building?
Yes. Rabatex customizes the VLM to the height available in your space. Tray height is adjustable, and the machine height is determined by it. At Meload Works, each VLM has two access points, one on the ground floor and one at a 6-meter-high assembly area.
Can a VLM connect to my ERP system?
Yes. The Rapid VLM runs on indigenous inventory software with multilevel tracking and can be integrated with ERP systems such as SAP. Trays are barcode-identified, so stock records stay accurate and traceable.
How long does it take to install a Rabatex Rapid VLM?
In this project, installing one VLM took roughly 15 to 17 days after it was unloaded at the facility, followed by a demonstration and trials.
Is the Rabatex Rapid VLM made in India?
Yes. Rabatex designs and manufactures the Rapid VLM in-house at its Ahmedabad facility. The hardware is built in India, and the inventory software is indigenous.
Does Rabatex provide training and support after installation?
Yes. For Meload Works, Rabatex handled installation, commissioning, a demonstration, trials and operator training. Rabatex also provides technical support and after-sales support.