The Hidden Cost of ASRS Crane Downtime

Unplanned downtime is rising — and older systems are the culprit.

As older ASRS (Automated Storage and Retrieval System) cranes age out of serviceability, manufacturers face a silent but growing liability: unplanned downtime.

Many facilities are operating with crane systems installed 15–20 years ago. While these workhorses may still be “operational,” the reality is that outdated components, obsolete controls, and limited parts availability are ticking time bombs. When these systems fail, they don’t just interrupt material flow—they ripple across your entire operation.

This post breaks down the true cost of ASRS crane downtime, highlights which legacy systems are at highest risk, and shows how you can access modern replacement solutions with minimal disruption.

Downtime Isn’t Just a Technical Issue—It’s a Financial One

Downtime on an ASRS crane system is rarely isolated. When one crane goes down:

• Inbound or outbound material flow stops

• Buffer zones overflow or stall

• Forklift traffic increases, increasing safety risk

• Labor must be reallocated or idled

• Shipments get delayed, customers get frustrated

Here’s what that downtime might look like in hard dollars:

Downtime Scenario	Estimated Cost Range
1 crane down for 8 hours	$8,000–$50,000+
Emergency repair visit	$5,000–$15,000
Missed shipments / SLA penalties	$10,000–$100,000+
Customer churn from delays	6–7 figures annually

Legacy Crane Systems: High Risk, Low Support

Many ASRS crane OEMs from the 80s, 90s, and early 2000s are now out of business—leaving customers without parts, support, or upgrade paths.

Common Legacy ASRS Brands No Longer in Operation

Defunct ASRS OEMs

Munk

Interlake

HK-Systems

Digitron

OWL

Köttgen

Lalesse

Locker

FATA

Demag

FKI-Cleco

Noell

Alstef

Eisenmann

Direct Dambach Replacement Crane Compatibility

The good news? Dambach offers direct-fit replacement cranes for many of these legacy systems—providing modern performance with reduced install complexity. As an authorized Dambach partner, Elite Robotics can help scope, plan, and implement these replacements with minimal disruption.

ASRS OEM	Dambach Direct Replacement Available
Munk	✅
Interlake	✅
HK-Systems	✅
Digitron	✅
OWL	✅
Köttgen	✅
Lalesse	✅
Locker	✅
FATA	✅
Demag	✅
FKI-Cleco	✅
Noell	✅
Alstef	✅
Eisenmann	✅

Partnering on PM, Service, and Replacement

As your crane ages, your best defense is a proactive strategy:

• Schedule recurring preventative maintenance

• Audit your crane’s controls, drive systems, and wear zones

• Evaluate retrofit or replacement options

• Work with partners who support both legacy systems and modern replacements

Final Thought: Don’t Let Obsolete Systems Hold You Hostage

Downtime doesn’t need to be your default. If your crane vendor no longer exists, or support is slipping, let’s talk. Whether it’s service, upgrades, or a full replacement, we’re here to help you move forward—with confidence.

📩 Contact Elite Robotics & Automation — and we’ll provide a quick compatibility check and roadmap.