Bulk within the Warehouse Management System

What is bulk storage within a WMS?

Bulk storage refers to the storage and handling of goods that are kept in large volumes or without individual packaging, such as powders, granulate, liquids, gases or big bags. The WMS from Adaption registers all activities: inbound with weighing or volume measurement, storage in silos or bulk locations, batch and lot management, internal relocations and the eventual outbound to transport means. The system delivers real‑time inventory levels and full traceability, and links directly with transport and billing systems.

Adaption’s WMS for bulk goods

How does the WMS register bulk goods?

The Adaption WMS records every step within bulk logistics: receipt, quality inspection, measurements (volume/weight), location management, internal movements and outbound. All changes are logged automatically, thereby ensuring accurate inventories and full traceability.

Support for inbound, storage and outbound

Bulk processes are fully supported within the Adaption WMS. Upon inbound the system processes all relevant data, including weighing data, volume changes and batch or lot information. During the storage phase the WMS continuously monitors location data, silo or tank levels and quality parameters. At outbound the system automatically creates loading instructions, integrates with transport planning and generates the required documentation.

Additional functionalities for inbound, storage and outbound

Effective bulk management requires that all incoming and outgoing goods are precisely registered and controlled. The Adaption WMS supports this process with the following features:

Specific loading and unloading lists: The WMS generates structured loading and unloading lists so that staff can clearly see which bulk goods must be unloaded, stored or loaded. The lists contain batch information, location codes, loading volumes and safety or quality parameters.
Complete registration of inbound and storage: During inbound the bulk goods are automatically weighed or measured volumetrically. The system immediately logs the inventory, links it to the correct location or silo, and monitors levels or mass balances. This prevents under‑ or over‑booking and increases inventory accuracy.
Re‑packaging and processing of bulk goods: When bulk goods need to be repacked, for example from silo to big bag, or from tank to smaller IBCs, the WMS registers all volume changes and batch relationships. As a result inventory and quality data remain fully traceable, even when goods are split or combined.

Different types of bulk goods

Categories within bulk logistics

Different categories of bulk goods are processed within bulk logistics. Dry bulk, such as granulate, sand, grains and powders, is often stored in silos, bunkers or big bags and requires precise volume measurement and batch registration. Wet bulk, such as liquids, demands level monitoring and registration of temperature or density. Gases or semi‑bulk flows can also be processed within the WMS. Adaption supports full registration of inbound, storage and outbound for all types of bulk goods in one integrated environment.

Construction materials:

Materials such as sand, gravel, cement and granulate are stored and processed in large quantities. These goods are typically weighed and managed in kilos or tonnes. The Adaption WMS records all inbound and storage operations, including weighing data, location management and any volume changes.

Powders:

Examples include flour, sugar, starch and various chemical powders. These substances are usually stored in silos or bulk compartments and measured in kilograms or tonnage. The WMS supports volume measurement, batch and lot registration and traceability during storage, processing and outbound.

Liquids:

Liquids such as oil, milk, chemicals or other wet bulk flows are stored in tanks, IBCs or special containers. The amount is recorded in litres or cubic metres. The Adaption WMS handles level measurements, quality parameters (such as temperature or density) and links inventory levels directly to transport and loading processes.

Gases:

Industrial gases such as propane, nitrogen or oxygen require specialised storage and safety procedures. They are often measured in litres or cubic metres based on pressure and volume measurements. The WMS supports registration of inventory changes, safety parameters and location management within gas‐storage installations.

Other bulk types:

In addition there are bulk goods such as granulates, pellets and mixes that require specific storage or processing methods. The Adaption WMS records all relevant parameters from inbound to processing and outbound so that inventory management and traceability across various bulk types remain accurate.

Storage options for bulk goods

Bulk goods require specific storage methods to ensure quality, safety and accurate inventory registration. The Adaption WMS supports various storage forms and records all relevant parameters such as volume, weight, batch information and level measurements.

Silo storage:

Silos are often used for dry bulk products such as grain, flour, granulate, powders and cement. They offer a controlled storage environment and allow vertical storage with optimal space utilisation.

Tank storage:

Tank storage is suitable for liquids and chemical products that require temperature or pressure monitoring. Tanks are monitored for levels, density and quality.

Big Bags and sacks:

Bulk goods such as powders, pellets and granulates are often stored in big bags or sacks. This allows flexible handling and accurate location layout within the warehouse.

Loose storage:

Loose goods such as sand, gravel, crushed rock or minerals are stored directly on the ground, in bunkers or in special storage areas.

Packaging and transport options for bulk goods

Bulk goods are packaged and transported in various ways, depending on their physical properties, safety requirements and logistics process. The Adaption WMS supports all these variants and records for each goods stream the associated activities such as loading, weighing, batch information and transport links.

Tank trucks and tank containers: Tank trucks and tank containers are used for the transport of liquids and industrial gases over short and long distances.
Intermediate Bulk Containers (IBCs): IBCs are suitable for liquids, semi‑liquid products and fine‐mesh bulk. They are easy to handle, reusable and fit within pallet positions.
Drums and barrels: Drums and barrels are used for chemical products, oils and hazardous materials, where accurate registration is essential. The Adaption WMS records:
Big Bags and sacks: Big bags and sacks are widely used for powders, pellets and granulates that need flexible movement.
Pallets: For smaller bulk packaging, semi‐finished products or finished bulk product pallets are used.

Value Added Services (VAS) for bulk goods

Bulk goods in various sectors are not only stored or transported but also processed or handled before they continue in the chain. The Adaption WMS supports these Value Added Services (VAS) by logging every operation in full, including batch and lot data, volume changes, quality parameters and downstream flows.

Extraction (separating components)

Extraction is used when one bulk product must be split into several components, for example in the chemical or food‑industry. The WMS logs:

incoming bulk quantity
outgoing flows per component
batch and quality data
mass balance and inventory changes

Blending (mixing bulk materials)

In blending, different bulk products are combined into a new composition. This is crucial in the chemical, agricultural and food sectors. The WMS supports:

registration of the used components
volume changes after mixing
batch creation and traceability
quality registrations and release

Melting (melting bulk products)

Some bulk goods are melted in order to better process or transport them. The WMS records:

temperature and process parameters
input and output volumes
transitions between states of aggregation
documentation for processing or transport

Drumming & packing (filling and packing)

In drumming and packing bulk goods are filled into drums, barrels, sacks, big bags or other packaging. The WMS records:

filled quantities
batch and packing data
location management of finished product
consolidation and loading instructions for transport

Our WMS offers an integrated solution for the complete management of bulk goods, from storage and transport to additional processing. This ensures that companies achieve maximum control and efficiency in their bulk logistics.

Example of bulk registration in the Logistics Cloud Suite

The following example shows how bulk processes and associated Value Added Services (VAS) are logged in the Logistics Cloud Suite from Adaption. The system logs every step of the process, so that all inventory changes, quality data and traceable operations are fully visible.

Step 1: Inbound registration

When bulk goods are received the volume or weighing data are recorded, together with lot or batch numbers, supplier, product information and any quality parameters. The goods are then assigned to a temporary location or processing unit.

Step 2: Selecting an empty unit

The system automatically identifies available units, silos, tanks or packaging carriers that are suitable for the type of bulk product. The operator selects the correct unit, after which it is immediately linked to the inbound process.

Step 3: Carrying out the VAS operations

In this example two operations are performed:

Flushing
Here the unit is cleaned or cleared of residual material. The WMS logs the operation as a process step, including time, operator and any material disposal so that mass balance and quality registration are correct.
Filling
Subsequently the unit is filled with the correct product. The system captures the exact quantity, batch information and any quality data (such as density or temperature). Any volume mutations are automatically processed into inventory.

Step 4: Storage in the warehouse

After processing the unit is stored in a silo, tank location, bulk position or pallet location.

The WMS logs:

the assigned location
inventory level in the unit
process history
subsequent logistics steps (e.g. loading instruction)

Step 5: Traceable process overview

All steps from inbound to storage and VAS are displayed in a process log.

As a result the full chain remains traceable and the processes meet quality, audit and compliance requirements in bulk logistics.

Efficient and transparent transport management is no longer a luxury, but a necessity for every shipper who wants to grow and compete. With Adaption’s powerful Transport Management System you not only optimise your daily processes but also increase customer satisfaction and reduce operative costs.

Do you want to learn more about how these methods can improve your logistics?

Contact us for a no-obligation consultation or schedule a demo. Together, we will achieve your logistics goals and support your company’s growth!

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