Vanderlande has been selected by Kmart to automate its new logistics facility at the Moorebank Intermodal Precinct in Sydney. To meet the complex needs and demands of one of Australia’s most iconic retail brands, the state-of-the-art warehouse will feature Vanderlande’s FASTPICK goods-to-person
order fulfilment system.
The Kmart Group serves millions of customers per week in over 450 Kmart and Targetstores across Australia and New Zealand, as well as through its online platforms and mobile apps. Kmart’s long-term growth ambitions will focus on this omni-channel approach, and address the current challenges of labour availability, rising order volumes, and increasing customer expectations.
The partnership reflects Kmart’s commitment to enhancing operational efficiency and future-proofing its supply chain as it continues to expand across the region. The new 100,000m² omni-channel facility will be equipped with Vanderlande’s advanced FASTPICK solution, combining the intelligent ADAPTO automated storage and retrieval system (AS/RS) with ten ergonomic goods-to-person (GtP) workstations.
The system has been designed to maximise picking speed, flexibility and efficiency, so that the full complexity of both business-to-business (store deliveries) and business-toconsumer (online orders) operations can be seamlessly integrated within a single omnichannel fulfilment centre. For retail distribution, a high-speed crossbelt sorter will handle both cartons and polybags with a high level of precision.
In addition, the Moorebank site will deploy a large fleet of Toyota AGVs and VNA (very narrow aisle) trucks to support internal pallet transport and high-density storage. The entire operation will be controlled by Vanderlande’s VISION warehouse control system, ensuring the intelligent coordination and
management of all processes. Together, these integrated technologies will form a scalable, future-ready platform that is tailored to meet Kmart’s operational requirements.
“The investment in the new Moorebank omni-channel fulfilment centre will be an important part of our long-term strategy to modernise our supply chain and simplify store operations,” explains Phillip Irvine, Kmart’s General Manager – Next Generation Supply Chain. “Ultimately, this approach is about delivering even more value to our customers, which is central to who we are.”
“We are excited to join Kmart on this journey to optimise its supply chain and ensure that this is ready for the future,” says Jordan Thrupp, Vanderlande’s Managing Director Australia. “The strong partnership we’ve built with their team has been instrumental in delivering the best possible solution, and we remain committed to supporting Kmart’s ongoing success.”
Stephan Heessels, Vanderlande’s Executive Vice President for Warehouse Solutions adds: “This project reflects our dedication to delivering scalable systems with fast and efficient order fulfilment. FASTPICK is the optimal solution for leading retailers, such as Kmart, facing unpredictable long-term growth across their store and e-commerce operations.”
Bold new branding for end-to-end system integration specialists TGW Logistics represents confidence, flexibility and dynamism for a formidable presence in European and global logistics. Paul Hamblin hears about it.
The demands on logistics professionals may one day overwhelm. Take LogiMAT: now up to 10 halls (and counting), and with AI and robot technology making ever more outlandish promises to potential customers, how do you process what is actually real and what is not?
It is a landscape in which TGW Logistics – presenting new branding colours and shapes for an ever-changing world – promises an established, reassuring presence. “We are real. What you see is what you get,” says Jan-Willem Klinkenberg (pictured, below), Head of BizDev Northern Europe for the Austria-based global integrator.
End-to-end Integration
Let’s dig down into that reality a little. TGW describes itself as an end-to-end integrator, a term bandied around liberally in the marketing literature of many materials handling companies. What does it mean, though?
“It means we take full responsibility for the change your company is going through,” he defines. “Yes, that change is centred around warehouse automation, because that is our core business. But it’s important to bear in mind that we start by looking at the shed, the warehouse, as a total entity. The basic processes inside that shed comprise inbound, quality control, storage, picking, packing and shipping and this is where we will analyse the customer’s data to explore areas where we can deliver significant ROI via automation. Most of the time, but not always, this focuses on the picking and packing of small goods.”
Automation should not be simply dismissed as fewer people and more robots. Integration for experienced providers such as TGW Logistics is about partnering the customer to evaluate how to best deliver greater efficiency, speed, sustainability, flexibility and cost control. It can come in many forms.
Jan-Willem Klinkenberg, TGW
He illustrates: “One of the projects I’ve been involved with recently was a 50,000 sqm warehouse, in which we use just 8,500 sqm for automation. But 80% of the order lines go through the automation. The customer said to us, ‘Thank you, it’s fantastic, business case proven, budget and investment all signed off; now, can you help us with the other 41,500 square metres?’ They wanted us to deliver the WMS for the manual picking and packing areas, to support them in selecting the right pick and pack areas for what they called the heavy and ugly stuff, also for the pallet racking, the pick towers. That is real integration.
“Of course, the most added value for ourselves sits in the automation part, because that’s our core, it is our own kit that we have developed, produced and delivered. But ultimately we served this customer in a much wider journey to integrate five DCs into one new warehouse. It was a fantastic project, and I’d love to do more like it.”
An end-to-end integrator worthy of the definition needs agility to meet the demands of many types of customer, he explains.
“At the other end of the scale, for instance, we work with a major global ecommerce retailer, also a great customer and with fantastic projects. The added-value is a bit lower for us in their case because they have their own very accomplished in-house design teams. But they know exactly what they need from us, and so we are a significant system integrator for them, but without providing the full end-to-end processes and solutions.
“We are flexible to meet all needs – and we need both of those types of customers for our business.”
Automation is not new, of course. The technologies now refined and improved by TGW and others today have now been around for two, even three decades. Consequently, many new projects do not comprise the familiar ‘manual to automated’ transition, but a ‘legacy’ automated system to a state-of-the-art model. Decision-making is therefore on the agenda for many of those pioneers of the early 2000s.
“Take the UK, for instance. Some outstanding legacy systems were delivered to major retailers in the early years of this century. These businesses learned a long time ago the ROI potential and added value of automation. Now, 20 years later, they are in possession of outstanding technical equipment which is still there and which is still working perfectly. But they still have a decision to make in terms of remaining cutting-edge. What do they do? Do they buy new, do they reconfigure, do they dismantle?”
Easy decision, he reveals.
“Let me give you an analogy. Forty years ago, my mother and father bought a washing machine when they got married. And it’s still going strong. My father is so proud of it – ‘I replaced this, I replaced that, it’s still running!’ – and I said to him, ‘Dad, it uses five times as much water and 10 times as much energy than the latest models. Yes you’re doing OK, but if you get a new one you use less energy, less water and you’re going to make money.’”
Hardware and Software Expertise
TGW Logistics has evolved to suit customer needs as technology, habits and demands have changed. Founded 55 years ago in Austria, TGW was originally a small metalworking shop in the city of Wels; ‘software’ was barely a word in the dictionary. No longer. As software became an essential in the automation package, so TGW partnered with and then acquired specialist software companies, enabling it to accelerate and refine its in-house R&D investment.
“I always say that electro-mechanical equipment from TGW is the best in the world,” claims Klinkenberg. “That is not just sales patter; I can say it with proven confidence, because we have delivered to so many companies who are now massively successful in their own right, names such as Witron, Knapp, Vanderlande, SSI Schaefer.”
But the role of the right software, correctly applied and managed, is absolutely vital, he advises.
“Software comprises between 8-12% of the investment of an integrated system, but I believe 80-90% of the success of that system is down to the software. So it is of paramount importance. And a huge chunk of this importance is change management.
“The uninformed think that the integration and automation process is like buying a new car. Pick up the keys, jump in, drive away. That is categorically not the case here. It takes 6-12 months to make your assets sweat, to fully understand its dynamics and how it will work best for you. It’s the software that enables us to see what’s happening in real time, providing the customer with the evidence to improve future operations.”
Key Market Areas
TGW will apply itself to any relevant challenge in any sector, but is focused in four key areas: Grocery, Fashion/Apparel, Industrial and Consumer. The company has been a key part of the revolution in Grocery and Fashion over recent years.
He believes Grocery is advanced and well-defined. “It’s clear who all the players are. In the Nordics, Benelux, UK, you can count them on one hand or maybe two, all have invested in automation and all have already seen the added value of automation.
“In terms of coming trends, we’re noticing that some of our customers are trying to secure long-term partnerships with us for similar reasons. They all have the same issues: lack of labour – no one wants to work at night or in a deep freeze – so automation is the obvious answer. That means they need materials handling partners. In the Grocery sector, this translates to large-scale projects Those are good projects for us, we have the scope to take part in those tenders.”
In the Fashion sector, it’s no secret that a lot has happened over the past five years. “Covid was a massive factor. Ecommerce accelerated much faster, and now we’re seeing some evidence of the opposite happening as people show more willingness to go back to bricks and mortar stores for fashion items.” Omnichannel is therefore still very often the order of the day in fashion retail.
“As logistics experts we have to be able to deal with that, which means we need to be as flexible, scalable, and modular as we can with our solutions. Customers need to be able to handle single line orders, they need to be able to handle 25 or more lines.”
He explains that some of the new brands in fashion are very strong in marketing and sales but less so in logistics, thus presenting exciting opportunities for 3PLs. “You’ve seen 3PLs investing more in automation, in shuttle systems for instance,” he points out.
TGW’s latest tagline for its customers is ‘It’s Possible’. It’s a claim the company can make from a position of strength. Unlike some integrators, TGW develops and constructs all of its own equipment and hardware, backed by its own proprietary software. Crucially, the company is run as a Foundation, meaning that all decisions are taken for the good of the future health of the company, its people, customers and community, not to promote or protect a share price. That is a powerful starting place.
Finally, it’s projects are about partnerships. Customers learn from TGW experts; TGW is always learning from its customers. In that environment, everybody wins.
Automated picking and handling operations often require the usage of more than one technology in the robotic area. They should be both scalable and flexible. David Priestman got an update from a key player.
“We’re experts in the hardest area, which is individual item picking,” Ocado Intelligent Automation (OIA) CEO Mark Richardson told me when we caught up with each other at LogiMAT. Having seen the hive OSRS storage and retrieval system close-up myself it is impossible not to be highly impressed by it. With OIA firmly planting its flag in the global materials handling industry, exhibiting at both LogiMAT and ProMat, having both the right mix of products combined with the best route to market is the name of the game now.
Robotic Area
As well as selling directly to non-grocery customers internationally OIA is going to leverage resellers to grow market share. The first deal announced, non-exclusively for the German-speaking market, was with Gebhardt Intralogistics Group. Gebhardt has a wide range of excellent handling and conveying systems, but not an ASRS. “We don’t have presence in Germany, so we’re looking forward to having access to a market that probably wouldn’t (readily) talk to us,” Richardson said. “It gives reassurance to customers that we have a presence. Gebhardt has a stellar reputation in the sector and across Europe, and we trust them to bring deep value and expertise to customers in the region. They have good mid-size capability.”
OIA is in discussion with a small number of other resellers internationally. “It was always our plan to use resellers,” Richardson added. “We’re picky about who.” He anticipates doing projects lead by and sold by Gebhardt (and other resellers) but also vice-versa, with OIA winning the business and taking the lead, utilising local installation, service and maintenance. Expect more announcements.
Call the Porter
The company is extending the ‘Chuck’ range of AMRs to automate further processes. ‘Porter’ is a new AMR pallet-carrier that drives pallets point-to-point, all using the Chuck tech-stack. Porter picks, moves and places pallets directly from the floor with precision, even when they are aligned back-to-back. It recognizes its surroundings to safely handle and transport heavy loads autonomously and can be configured to handle cages, increasing flexibility and expanding fulfilment capabilities.
“Customers might buy just the Porter or Porter plus Chuck,” Richardson informed me. “In existing operations it can be used as an inexpensive palletmover, collecting open or closed pallets and it can stack pallets immediately adjacent to each other, so there are no gaps. Porter takes us into the case handling and de-palletising robotics area, extending our product range. It will be used for inbound, from the dock door to the OSRS induct stations and loading into the grid – bringing the pallet to the decanter.”
Porter’s advanced vision system enables it to navigate safely and autonomously without requiring infrastructure changes or manual intervention. Moving at speeds of up to 4.5 miles per hour, the AMR dynamically adjusts its speed when detecting people or equipment in the area, ensuring workplace safety. Porter intelligently parallel parks itself in aisles to reduce congestion, keeping operations seamless for both robots and human associates.
Finally, I asked Richardson for an update on OSRS projects being delivered. Canadian pharmaceutical distributor McKesson’s installation will be finished this summer, ready for final testing and go-live. “We have a full pipeline,” Richardson stated, “as well as bidding for many projects.” Watch this space and listen to our Logistics Business Conversations Podcast with OIA on Spotify and other platforms.
German storage system and sawing machine manufacturer Kasto, through its UK and Ireland subsidiary in Kibworth Harcourt, Leicestershire, has announced its expansion into a new area of activity with the launch of the UNITOWER cnc. The innovative tower storage and retrieval system automates the transfer of plates carrying fixtured workpieces to machining centres, as well as the return of machined components to the store.
Suitable for automating one or more machines of virtually any make, the tower can hold fixtured components of considerable size on multiple levels in a compact footprint to a height of up to 20 metres. Operators are able to prepare fresh fixtured workpieces on plates at separate adjacent setup stations while machining is in progress. In this way, costly downtime is eliminated and productivity and profitability are raised by allowing the entire system, including high-value machine tools, to operate for extended periods.
Each shelf measuring 3 x 1.5 metres in the tower accommodates one or two plates, depending on the size of the fixtured workpiece, while load height is anywhere up to 1.7 metres, subject to a maximum supported weight per shelf of five tonnes. The plates have a zero-point clamping system on the underside for precise location on the pallets of twin-pallet-change machining centres, which saves the cost of having multiple expensive machine pallets in the system. In any case, their depth would take up more vertical space in the tower than the thinner plates, resulting in fewer parts stored.
An overhead gantry crane in the tower automatically accesses a plate loaded with fixtured workpieces, which is transferred to the locations assigned by the controller via shuttle units and roller tracks configured to suit the application. In comparison to a paternoster system, the gantry crane has the advantage that only the targeted shelf is moved, rather than all of them, ensuring fast access times and saving energy. Before each plate arrives at a machining centre, it is automatically positioned onto one of the machine pallets prior to its entry into the working area. Partially and fully machined workpieces are returned to the tower in a similar manner.
The UNITOWER cnc is managed by KASTOlogic, the manufacturer’s proprietary software for warehouse management and production control. It ensures machines are provided with the workpieces required for each order, checks whether the necessary NC programs and tools are available, monitors production processes, calculates completion dates and determines the optimum sequence for handling orders.
When developing the UNITOWER cnc, Kasto leveraged extensive experience gained in its own factory in Achern, southern Germany. A practical, safe, sustainable automation solution emerged that is suitable for manufacturers in all sectors. As it is of modular design, the storage and handling system can be expanded virtually without limit – a major advantage for growing companies.
Moffett Automation was founded in 2017 with a small, dedicated team and a vision for innovation and global impact, writes Shane Clarke.
“Since those early days our ambitions have driven remarkable growth: today, we are proud to employ over 100 talented professionals who contribute to our expanding portfolio of industry-leading solutions. Our engineering excellence has garnered significant recognition, highlighted by the 2022 Manufacturing Supply Chain Awards. This momentum continued in 2023 when Ernst & Young honored our Managing Director, Sam Moffett, with the prestigious ‘Entrepreneur of the Year’ award in Ireland. Building on this achievement, Sam was subsequently nominated as an International Entrepreneur of the Year contender in 2024.
“As our expertise and reputation have grown, so too has our global reach. Our Moffett Taxi Systems (pictured) have been implemented in over 20 locations worldwide, establishing our presence as a trusted partner in automation on an international scale. Each system reinforces our commitment to excellence and demonstrates our ability to deliver high-quality, cutting-edge technology solutions that meet the evolving needs of the warehouse and logistics industries. Our global footprint continues to expand as we work with partners and clients across multiple sectors and territories, ensuring that our solutions remain at the forefront of efficiency and reliability.
“Our fully automated warehouse storage solutions are powered by our highly regarded four-directional Moffett Taxi pallet shuttle. This system revolutionizes warehousing by optimizing space, reducing manual labor, and increasing operational efficiency. We take great care to understand the unique needs of each customer, designing and implementing bespoke pallet storage solutions that align perfectly with their requirements. Our customer-centric approach ensures that each solution maximizes productivity and streamlines operations.
Seamless movement
“The Moffett Automation VTUs (Vertical Transfer Units) allow our taxis to move seamlessly in all directions. These VTUs enable the taxis to travel between multiple levels, ensuring that any taxi can carry any pallet to any storage space within the system. This innovative flexibility eliminates bottlenecks and enhances the overall efficiency of warehouse operations. Our customers benefit from a system that not only optimizes storage capacity but also delivers unparalleled speed and reliability.”
Each Moffett Taxi is engineered to handle heavy pallet loads of up to 1500kg, demonstrating its robust and durable design. The system is also built to withstand challenging environments, operating efficiently in temperatures as low as -25°C, making it ideal for a wide range of industries, including food storage and pharmaceuticals. The taxis boast an operational period of 8 hours in ambient storage conditions and 6.6 hours in chilled storage, ensuring that they maintain high performance levels even in the most demanding settings.
“Our cutting-edge software plays a crucial role in the functionality and reliability of our automation systems, adds Clarke. “It enables remote monitoring and control, allowing for real-time adjustments and preventative maintenance. Key features include automated heat sensor monitoring, motor deceleration and acceleration adjustments, and remote operation. This guarantees rapid response to any technical issues, minimizing downtime and preserving system integrity.
Pallet Taxi
“One of the defining aspects of Moffett Automation is our commitment to in-house manufacturing. The Moffett Taxis, VTUs, and conveyors are built at our factory in Ireland, giving us the control to maintain the highest standards of quality and innovation.
“Looking forward, Moffett Automation remains dedicated to pushing the boundaries of warehouse automation. Our ongoing investment in research and development ensures that we continue to lead the industry with pioneering solutions. By leveraging cutting-edge technology, engineering excellence, and an unwavering commitment to customer satisfaction, we are shaping the future of automated storage and logistics on a global scale.”
Gebhardt Intralogistics Group and Ocado Intelligent Automation (OIA) are entering into a relationship wherein Gebhardt will provide the Ocado Storage and Retrieval System (OSRS) to customers in Germany, Austria, Switzerland, and other territory where it operates. The non-exclusive collaboration also positions Gebhardt to provide installation and maintenance support services for the OSRS.
“To continue our growth in the global logistics and supply chain market, we welcome Gebhardt into the Ocado Intelligent Automation ecosystem as a solutions provider,” said Mark Richardson, CEO of Ocado Intelligent Automation, part of Ocado Group. “Gebhardt has a stellar reputation in the sector and across Europe, and we trust them to bring deep value and expertise to customers in the region.”
The OSRS is an ultra-high-density cubic storage and retrieval system that combines world-proven automation with advanced warehouse execution software. It seamlessly integrates Ocado’s unique Robotic Pick technology, which is already deployed at scale and has performed billions of real-world picks.
The system’s ability to manage and scale high throughput operations makes it an excellent solution for a wide variety of industries, especially fashion and apparel, e-commerce, distribution, pharmaceuticals, and healthcare organizations, which need to efficiently process and pick a large volume across a wide product range.
The OSRS claims market-leading storage density, and its lightweight grid structure supports a bin capacity of up to 21 bins high. Because it’s modular, systems providers and logistics teams can deploy it at any scale, safe in the knowledge that the OSRS can expand as their operations evolve.
“Gebhardt has been seeking a high-throughput cubic ASRS to add to our portfolio. The Ocado Storage and Retrieval System fills that unique need, empowering large-scale fulfillment operators to compete at the next level,” says Marco Gebhardt, CEO of Gebhardt Intralogistics Group. “This is what the 70-year Gebhardt reputation is built on, providing a wide variety of flexible, modular solutions to support customers as they grow.”
“Integrators can play an essential role in the adoption and successful execution of advanced robotics and automation,” added Monique Apter, Chief Revenue Officer, OIA. “Gebhardt and OIA share the same outlook on customer relationships. Their highly trained experts will be on the ground, engaging with customers, providing service, and training associates in a meaningful way that’s rooted in the knowledge of how those customers like to work.”
The national logistics division of Swiss food retailer Migros is expanding its highly automated dry goods distribution center in Suhr with WITRON. The integration of 14 additional COM machines into the existing solution during ongoing operations is claimed to be a logistical, architectural, and sustainable masterpiece.
The logistics area required for this is being built on the roof of the dispatch station, which is adjacent to Migros Verteilbetrieb AG (MVB), Suhr so that no additional space needs to be sealed for the expansion. Starting in the third quarter of 2027, the additional technology will enable MVB to pick almost 132,000 additional cases onto store pallets fully automatically every day. The facility in Suhr will then pick more than 560,000 cases on a peak day using a total of 47 COM machines in combination with WITRON’s DPS and ATS solutions.
The project known as “FOODTURA” was a challenging task for WITRON’s logistics designers, as only 7,000 square meters were available for the expansion. A total of 14 fully automated picking machines, 116,000 tray storage locations, 28 stacker cranes, 6 depalletizers, and 4 stretch-wrappers had to be integrated – spread over two levels. Given these specifications, MVB and all architects involved have elaborated a solution that sets standards in terms of both functionality and design.
Integration of 14 additional COM machines
The new logistics area will be connected to the existing one via a compact conveyor system network. “MVB has been storing and picking dry goods in Suhr since mid-2011 with a WITRON OPM system at Champions League level”, explains Alexander Schweizer, Head of Engineering and IT at MVB. “From there, we currently supply more than 700 stores with 315,000+ cases daily.” At the end of 2015, an automated solution for the fresh produce and convenience sectors was integrated into the existing building, enabling almost 120,000 cases to be picked every day.
“With the OPM solution, we have achieved a high level of cost-efficiency and store service in recent years – and, as a result, a high level of customer satisfaction. Due to the expected growth, the decision was made to integrate 14 additional COM machines into the dry goods sector. This will enable MVB to pick an additional 132,000 cases per day in future”, explains Schweizer.
Migros Verteilbetrieb AG in Suhr is already operating 28 COM machines in the dry product range and 5 COM machines in the convenience sector. “By the end of 2027, a total of 47 COM machines – in combination with WITRON’s DPS (Dynamic Picking System) and ATS (Automated Tote System) solutions – will be stacking more than 560,000 cases onto pallets and roll containers every day almost error-free, store-friendly, ergonomic, and sustainable. Nearly 100 percent of the product range will be picked automatically”, says Schweizer.
Extensive IT project in Neuendorf
In addition to the OPM expansion at the Suhr site, the two companies also signed a contract for a comprehensive IT project at the Neuendorf site.
At the beginning of 2021, WITRON successfully implemented one of the world’s most efficient omni-channel distribution centers there as part of a challenging greenfield / brownfield project. The highly dynamic facility supplies more than 700 stores and many thousands of home shopping customers from a wide near-food / non-food range of 100,000+ different items p.a. On a peak day, WITRON’s OPM, AIO, and CPS systems pick 470,000+ cases, pieces, and bulky parts, which are dispatched both by truck and by rail. The facility also started the operation of a frozen goods warehouse, which uses OPM technology at minus 25 degrees Celsius to supply more than 1,400 stores from a range of 2,200 products and stack up to 100,000 cases daily store-friendly onto pallets and roll containers.
Intelligent software suite replaces existing solution
While the automated logistics areas in Neuendorf are already controlled by a WITRON WMS, the upstream and downstream logistics areas (receiving / shipping / returns handling) as well as all interfaces to the Migros SAP system and other higher-level systems (e.g. route planning, container pool management, statistics tools, etc.) have not yet been integrated into the WITRON platform.
As part of the end-of-life process, the existing solution in the near-food / non-food sector is now being successively replaced by a state-of-the-art WITRON WMS during ongoing operations. The future software suite is impressive end-to-end both functionally due to a high level of warehouse intelligence and through a high degree of usability and user experience – individually adapted to the tasks of the respective worker. This project should also be completed by mid-2027.
LogiMAT 2025 will take place at the Messe Stuttgart convention center from March 11–13, 2025. In Hall 3 at booth 3B67, Movu Robotics, member of the stow Group, will demonstrate its leadership in accessible and advanced warehouse automation. The showcase will highlight how Compact Scalability – an intelligent and adaptable concept for automated logistics systems – is redefining flexibility and efficiency in modern warehousing.
Movu Compact Scalabilty is a groundbreaking approach that seamlessly combines innovative robotics, intelligent software and state-of-the-art hardware to redefine how businesses meet their fulfillment demands. Movu’s scalable solutions maximize storage capacity within the same footprint while adapting effortlessly to the customer’s needs – vertically, horizontally, and with seamless integration. This scalability offers a key advantage, enabling businesses to expand their storage and throughput capabilities without requiring major overhauls to their existing infrastructure. Movu Compact Scalability empowers businesses to grow smarter, faster, and more efficiently.
Presented in Stuttgart, the Movu atlas ASRS is designed with modularity for flexible expansion. It can be added or removed on demand fluctuations, peak seasons, or business growth. The pallet shuttle system allows for incremental investments rather than a large upfront overhaul, making it cost-effective and highly efficient. As demand grows, the system can scale horizontally by additional aisles and lanes that can be seamlessly added.
Able to operate in temperatures between -25°C and 40°C, Movu atlas provides a solution for both ambient and cold store warehouses. It brings unmatched experience and expertise as the industry’s leading 2D shuttle provider. In the recent years, Movu successfully installed a huge number of shuttles in over 100 projects from all industries in Europe and North America. By adding an integrated Lift, the Movu atlas system transitions into a dynamic 3D storage environment and scales vertically ensuring compact scalability. As a result, throughput is boosted and valuable floor space is saved with high-speed lifts up to 2.5 m/s achieving faster replenishment cycle times and order fulfilment.
At LogiMAT 2025, Movu showcases, how the Movu atlas system with integrated Lift can be further expanded by the integration of a Picking Tunnel. The highly efficient and space-optimized pathway will be integrated into the ground level of a Movu atlas ASRS to facilitate streamlined order picking. Designed specifically for high-density pallet storage and retrieval, the tunnel enables seamless interaction between automated shuttles, vertical lifts and manual or robotic picking processes with autonomous mobile robots, such as Movu ifollow. The intelligent and versatile AMR operates autonomously, navigating without the need for any external infrastructure. Advanced sensors and mapping technologies allow the robot to adapt seamlessly to its environment. Equipped with cutting-edge obstacle detection and navigation systems and available in several models, supporting loads from 300 kg to 1.2 tons, ifollow can be tailored to meet specific operational requirement and operating in temperatures from -25°C to +40°C.
At the show, Movu also presents Movu escala, an all-in-one, rack-and-robot storage and retrieval system to handle totes. It maximises warehouse resilience by leveraging modular applications for unparalleled adaptability. Automatically moving up, down and within storage locations, each shuttle reaches up to five units deep. No need for space-consuming conveyors, lifts or aisles; this high-speed, high-density system is one of the world’s most flexible 3D ASRS for bins. Integrating seamlessly with Movu escala for future proof automated order preparation at the picking workstation, a new version of Movu eligo picking robot is a state-of-the-art robotic solution designed for high-speed and highly efficient item picking operations. It can pick up to 1200 items per hour, reduce the number of manual ‘touches’ required for order fulfilment or replenishment and can reach a pick success rate greater than 99%. Equipped with advanced vision systems, AI-based algorithms and versatile handling tools, eligo is tailored for modern warehouses that demand precision, speed and adaptability in dynamic environments.
In Stuttgart, Movu will also feature Movu Overfill Detection, an intelligent, camera-based vision system designed to ensure the seamless operation of automated storage systems for bins like Movu escala. This innovative solution identifies items and bins that exceed storage boundaries, preventing overfilled bins from entering the system and ensuring safe, uninterrupted operations.
Live-demonstration of future-ready warehouses
Stefan Pieters, CTO at Movu Robotics, commented: “At LogiMAT 2025, we will showcase our vision of Compact Scalability in warehouse operations. We are excited to demonstrate how accessible automation and integrated solutions deliver significant scalability advantages, enabling businesses to respond swiftly to market demands and optimize costs through incremental system growth. With stow supplying dedicated racking for Movu’s atlas and escala, our booth will unite Peak Performance Racking with intelligent automation. Visitors will experience firsthand how customers benefit from a seamless, single point of communication provided by a ‘one-stop shop’ approach, designed to achieve high-performance warehousing.”
As part of a company-wide digital transformation to overcome labour shortages, a leading Japanese 3PL company has commissioned an AirRob automated warehouse storage system from Libiao Robotics to serve its eCommerce business. The AirRob system is located in the company’s newly-built warehouse in the Tokyo metropolitan area, providing it with automated storage and retrieval functions for shoes, clothing, cosmetics and other products. This introduction is not only the company’s first installation of an automated tote handling system, but also the first AirRob system to operate anywhere in Japan.
Commenting on the decision to specify AirRob for the company’s new warehouse, its Business Manager said: “As Japan’s population declines, we need to expand our business scope. In order to strengthen the competitiveness of our logistics business, we focus on certain industries, especially improving our ability to handle a variety of small quantities of goods. In this trend, we expect to achieve the dual goals of high storage density and high operating efficiency, so when we first saw AirRob, we felt that this was exactly the solution we needed.”
Regarding the actual operation of the system, his colleague, the Director of the 3PL’s Innovation Promotion Office, expressed great satisfaction: “If we hadn’t used the AirRob system, we would have required at least 300 tsubos (about 1,000 square metres) of space, and the workers’ movement routes would have been very long, which takes a lot of time. Now we only need about 100 tsubos (about 330 square metres) to solve the storage problem. At the same time, employees don’t require too much training. They can operate by just staying at the workstation and scanning the code, so even those who join the company on the same day can start working straight away.”
As the warehouse is located on the third floor of a building, it was considered difficult to use automated equipment. However, in this regard the Business Manager said: “Even though we only have 4.5 to 5 metres of floor height here, we can store 6,000 SKUs in a 1,000-square-metre space. During the installation and deployment process, there was almost no change to the entire infrastructural environment, which has been a huge advantage.” Furthermore, AirRob’s lightweight design meant it could be installed on an upper storey of the Tokyo warehouse without compromising the load capacity of the floor.
Return on Investment
As Japan is one of the markets that is particularly affected by a labour shortage, the introduction of automated equipment must be precisely calculated. “Under the traditional model, the company often needed three forklift operators to handle 6,000 SKUs of goods , which was labour-intensive and time-consuming,” added the Business Manager. “After the introduction of the AirRob system, only one worker now operates calmly in the same working space. Not only has the labour cost been sharply reduced, but the operating efficiency has also increased exponentially, allowing the company to witness significant economic benefits in a short period of time. In addition, there is no need for additional electricity to drive air conditioners and other equipment in the storage area to maintain the environment, which effectively reduces energy consumption. After deploying this system, if expansion is required in the future, there is no need to re-lay power lines, etc.”
As part of its carefully planned mid-term business strategy, the leading 3PL company outlined two core development directions for its business. On the one hand, its focus is on analysing and strengthening the unique advantages of its logistics business by optimising processes and improving service quality; on the other hand, it is focusing on horizontal expansion, taking logistics as its foundation and actively exploring diversified business expansion paths to grow the company’s business territory.
In actual business operations, the company is keenly aware that it has accumulated rich experience in the field of multi-variety, small-batch cargo handling and this is where it has a unique advantage. It has found that the outstanding characteristics of the AirRob system are perfectly matched with this advantage. Its flexible storage architecture and efficient and smooth operation process not only meet the current small-batch and high-frequency logistics needs, but also offers strong scalability, providing a solid guarantee for the continued growth of future business and the richness and diversity of categories.
Logistics Technology Innovation
Over the years, this 3PL company has been at the forefront of logistics technology innovation and has worked hand-in-hand with its partners. From the initial introduction of the Libiao T-Sort 3D system at start of its exploration of automated logistics, through to the upgrade of the system in 2021 to optimise operations, mutual running-in and trust have gradually increased during this process. After initially deploying the T-Sort 3D system, the company experienced a significant improvement in sorting efficiency, saving 57% of space and helping it to become more and more receptive to Libiao’s solutions.
The addition of the AirRob system has now pushed this cooperation to a new level, leading the 3PL’s Director of the Innovation Promotion Office to say: “We still hope that Libiao can continue to launch innovative new products so that we can introduce them and turn them into our competitive advantage.”
At a ceremonial opening ceremony, Ms. Xia Huiling, CEO of Libiao Robotics, said via video link: “Today is not only the launch of a project, but also represents your attempts and recognition of new technologies. This cooperation is just a starting point. In the future, we will continue to work with you to create better solutions.”
The AirRob installation at this 3PL giant is the first of several new AirRob projects being installed in Japan in 2025, as warehouse robotics pioneer Libiao continues to achieve wider global acclaim for the many advantages AirRob holds compared to other AirRob-like systems.
Edward Hutchison, Managing Director of BITO Storage Systems UK, explains why successful automated warehouse solutions require careful consideration when choosing the racking.
The UK’s world leading e-commerce retail sector swells demand and raises expectations for rapid delivery but the sector is also in the midst of dealing with rising labour costs combined with a shallower pool of available skills for its warehouses. This is driving growing interest in automation among many more managers responsible for fitting out these facilities, particularly as the technology continues to become more flexible, bringing it further within reach of many more companies. In fact the UK will, by 2025, be Europe’s largest warehouse automation market at over £3bn, according to market research company Interact Analysis. That will be £0.71bn larger than in Germany, which has traditionally been far more automation friendly when it comes to warehouses. Another market researcher, IMARC Group, which put the UK warehouse automation market at USD 2 Billion in 2023, expects it to reach £4.6 Billion by 2032. That’s a growth rate of over 10% during 2024-2032.
Automation’s modularity, sophisticated control systems, and performance developments can create a more practical and flexible solution for a greater variety of applications – from fulfilling omnichannel retail to supplying line-side manufacturing. Stacker crane based automated storage and retrieval systems, for example, will provide high density storage on a given footprint within a warehouse to offer an efficient and safe goods to picker solution.
However, smooth operation of this software-driven warehouse technology will rely on the racking. Given it plays such a vital role in maintaining the flow for highly accurate and rapid order picking within a warehouse, racking should be carefully considered because the right design will help an automated system to realise its performance benefits. Reliable racking will also minimise maintenance and the subsequent costly downtime for an automated system, helping to improve its productivity and hasten the return on the investment.
Assessing the quality of racking starts with the basic components: the uprights and beams. Fine tolerances in the racking’s manufacture and installation are needed for the stacker crane to run smoothly, with trouble-free operation and maximum safety. Bolted frame components will allow a fast exchange of damaged components. Uprights need to be available in a range of widths and different material thicknesses to allow an ideal upright geometry for frame heights of over 20 metres and bay loads as heavy as 40 tonnes.
Suppliers using state-of-the-art machinery to manufacture racking components will produce all the elements at the exact required size and of a consistent quality and tolerance. This ensures long-term integrity of the racking system.
Ed Hutchison
The quality of the materials used in the racking will determine how an installation will stand up to the rigours of everyday operations. For example, galvanising and epoxy coating ensures high corrosion resistance and guarantees a long service life for all components. Safety is high on any list of considerations and starts with the integrity of the installed system, which is enhanced by stable floor anchoring, while pallet support bars add additional strength.
A supplier that can provide the bins and containers in addition to racking and shelving will offer the advantage of compatibility between these two elements. This will avoid numerous issues that can disrupt smooth material flow, such as bins not rolling properly down carton live flow lanes. It also makes it easier to achieve the maximum density of stock because multiple containers designed to fit precisely with a bay racking or shelving without leaving unnecessary gaps can generate considerable space savings throughout a warehouse storage area.
They will be able to supply specially designed bins and trays that have been adapted to automated racking and stacker crane conditions and meet the requirements of the system. For example, BITO XL series stacker containers, KLT small parts containers, and trays made from steel sheet or polypropylene, all meet the requirements of automated bin storage and are suited for any application.
Racking projects for automation will draw on a supplier’s experience and its ability to work with systems integrators and automation companies in addition to suppliers of other equipment and solutions, such as mezzanine floor and forklift truck companies. Reference site visits are a great way to assess the standard of a product in a working scenario. It is also useful to have a close look at the equipment in a showroom environment wherever possible.
Ultimately, when it comes to storage and order picking solutions, companies are seeking high quality – not just of the physical products, but also of the installation team and service support. As a customer about to make a large investment in automation, you really will need to take a careful look at racking.
