The topic of warehouse automation is currently occupying many companies - whether as part of planning a new system to replace manual processes or to supplement or replace an existing system. "When selecting the right technology, not only the usual factors such as item size, order structures or the required performance should be examined, but also the possibilities for integration into existing structures. This includes both the connection of the technology to the existing IT landscape and its implementation in the existing overall intralogistics system. In short, the solution must fit the process," emphasizes Peter Bimmermann, Managing Director AutoStore System Germany and Director Business Development DACH & CEE.

Anyone opting for an AutoStore as a small parts warehouse and fulfillment system can integrate the system into their material flows and processes in various ways, for example on conveyor lines, mobile transport robots such as AMR, automatic picking robots, reversible conveyors or elevators.

Conveyor connection with transfer cell

AutoStore is most frequently combined with conveyor technology. AutoStore robots pick up or transfer the bins directly to the conveyor system via the transfer cell. This enables transport to other areas, workstations can be individually designed, flexibly positioned and connected to other functional areas. The transfer cell also makes it possible to connect storeys and platforms, among other things.

AutoStore can also be installed on top of each other on platforms in order to use high halls efficiently or to integrate the system intelligently into the material flow. In this case, BinLifts handle the transportation between the levels. In this way, AM Logistic Solutions has implemented the compact storage of almost 150,000 bins with a high picking performance for the sporting goods manufacturer Erima. A total of around 3.5 million items are stored in the two-storey storage blocks in the new logistics center in Kirchentellinsfurt. Storage and picking to and from both systems takes place at carousel ports, which are connected to other storage areas via conveyor technology, including a Gebhardt shuttle as a sequencing buffer in front of the packing department.

Ludwig Meister, a supplier of drive technology, tool technology and fluid technology, was one of the first AutoStore users in Germany in 2013 and has grown continuously with the system. Following the first expansion in 2016, the specialist retailer most recently expanded its AutoStore from 40,000 to 60,000 bins and 37 robots during ongoing operations in 2022 and installed five new ports for incoming goods and picking. In order to make order picking more ergonomic and relieve employees of some packing and shipping tasks, the company has added a total of 200 meters of conveyor technology from the incoming goods area to the new automatic packing line. A transfer cell is also used to store the bins from the conveyor system in the AutoStore. For order picking, the cartons, which are now set up by machine, are moved ergonomically from the carton erector to the port via the conveyor system, where they are filled with the required items from the AutoStore and then transported to the automatic carton closing machine, which closes and labels each package in a volume-optimized manner according to the fill level. With AutoStore, the picking performance could be increased threefold to up to 6,000 picks per day - with room for improvement: Scaling up to 13,500 picks is possible.

Automatic order picking

Fully automated picking stations are a further step. So far, their share of the overall market is still small, but the trend is increasing, especially in logistics centers that operate in multiple shifts and are struggling with staff shortages.

AutoStore also focuses on integration with other technologies for new developments. The FusionPort with two removal openings and the FusionPort Staging with additionally connected conveyor technology introduced by AutoStore in spring 2023 represent a new solution for high-performance order picking.