Edward Hutchison, Managing Director of BITO Storage Systems, explains how robots can work with people to positively change the picture of traditional retail warehouse operations.
Counterbalanced and warehouse forklift trucks moving goods to and from storage locations in racking and shelving forms a familiar image of work inside a typical retail warehouse. But with drivers being a growing cost factor, some foresee this picture changing in the future. Many operations will of course continue to rely on forklifts, but automation is coming to the fore and, according to market intelligence company Interact Analysis, the UK is set to become Europe’s largest warehouse automation opportunity.
Driverless Internal transport systems are one such interesting opportunity because they are extending their role beyond merely transporting goods by gaining an ability to interact with racking and shelving, without the need for human intervention.
Edward Hutchison
Take BITO’s LEO flow, for example. This low cost, simple plug and play AGV (Automated Guided Vehicle) is equipped with a belt conveyor top and an automatic lifting mechanism, making it ideal for picking up and delivering goods to and from conveyor systems. Without the need for expensive software or infrastructure, it can carry a 600 x 400 mm load of either bins or small parts, which it can pick up and discharge sideways to the direction of travel using the belt automatically.
Goods can be fed directly to and from an Automated Storage and Retrieval System or LEO can deliver goods directly to the flow lanes of a Carton Live Storage system. Sensors allow bins to be transferred seamlessly from LEO to back of the flow lane, allowing personnel at the front of the lane to carry out the productive task of picking orders without running out of stock. With a payback period often in one year or less, this collaborative operation between people and robots is a great example of how a new image of work inside an retail warehouse can be created.
BITO UK, the UK subsidiary of the international BITO Lagertechnik GmbH of Germany, is looking ahead to the new year having experienced a record sales turnover in 2024.
The year saw BITO group establish a new pallet packing line in Poland to meet increased demand and the company was proud to achieve ISO 14001 – Environmental Management Certification in 2024. ISO 14001 is an internationally agreed and recognised standard for Environmental Management Systems (EMS). An EMS supports organisations in identifying, managing, monitoring and controlling environmental processes.
Product developments in 2024 included ECOMotion containers, which have been specifically designed for automated warehouses. They have a double base with a flat-surfaced, non-textured outer tread to minimise noise on conveyor lines and in automated warehouses. Also on the container front, all RK models are now manufactured in recycled plastic, further enhancing BITO’s renowned environmental credentials.
The spring of 2024 saw enhanced new versions of BITO’s cost effective Automated Guided Vehicle (AGV). LEO flow and LEO carrier offer vital advantages over manual handling and conveyor alternatives for transporting bins and containers, with a payback period often in one year or less. Less complex than more expensive AGVs, the new LEO flow and LEO carrier offer productivity advantages over manual handling and conveyor alternatives for transporting bins and containers, with a payback period often in one year or less.
Ideal for ecommerce picking operations, LEO carrier is equipped with a shelf that has four levels to hold goods being transported. LEO flow is equipped with a belt conveyor top and an automatic lifting mechanism. It has a maximum load capacity of 35 kg and a battery runtime of 10-14 hours. A 600 x 400 mm load of either containers, cartons or small parts can be picked up and discharged sideways to the direction of travel. Three reflective light barriers detect the position of the goods on the vehicle and ensure that the goods are centred before transport.
All that’s required for the plug and play LEO to get going is to lay a route marked by a 19 mm wide track line with tape or floor painting for the transporters to follow using optical navigation. Instructions are entered on a tablet and markers with printed QR codes guide LEO on destination points and tasks. Users can implement simple systems themselves in just a few days, without the need of IT support. And they can be quickly and easily adapted, enabling rapid reaction to seasonal fluctuations and warehouse reorganisations.
BITO has also enhanced its website, which has a fresh new look ready for a busy 2025. Visitors to bito.com can find comprehensive insight on BITO solutions, products, customer projects, advice and service information, thought leadership, case studies and news. They can also access the BITO online shop and direct catalogue – the fast way to a comprehensive range of materials handling products and solutions.
Edward Hutchison, Managing Director of BITO Storage Systems, said: “Finding efficiencies in warehouse solutions will be critical in the coming year as companies face increasing labour and energy costs. Retail developments are also challenging companies to hold sufficient stock within a given area and providing accurate and efficient order picking. Fortunately, BITO’s innovative spirit in developing solutions to meet these challenges will continue to develop in 2025. This will be the first of a series of important events throughout 2025 where BITO will be exhibiting, with the International Materials Handling Exhibition (IMHX) at the NEC, Birmingham on 9th – 11th September. We look forward to seeing you there.”
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.
