Storage process automation
Automation of storage processes is the foundation of modern logistics, allowing for maximum utilization of available space and the elimination of bottlenecks. Based on extensive experience in implementing advanced intralogistics systems for global leaders in the automotive and retail industries, we deliver solutions that revolutionize the flow of goods and components.
Automation of storage processes – response to the challenges of modern logistics
Rising costs of maintaining warehouse space and the growing shortage of operational staff mean that automation of warehousing processes is no longer an option, but a necessary condition to maintain market advantage. Traditional warehousing methods, based on manual labor and forklifts, are giving way to intelligent intralogistic systems in the face of increasing order dynamics. They guarantee error-free flow of goods and maximum utilization of available volume.
Investing in modern warehousing systems is primarily a change in the philosophy of goods management. Thanks to the combination of reliable drives with intelligent control, the warehouse stops generating losses resulting from errors or damage to goods, becoming a dynamic and highly efficient link in the supply chain. This allows for seamless handling of even the most complex processes while maintaining the highest safety standards.
Technologies on which we build solutions
Efficient logistics automation requires synergy between reliable control and precise execution. We integrate solutions from global leaders, ensuring full compliance with rigorous industrial standards.
Control Systems and HMI
Our systems are based on solutions from leading manufacturers. We design advanced operator panels and SCADA systems. We integrate, among others, Siemens, Allen-Bradley, and GE Fanuc controllers, which allows us to flexibly adapt the control logic to the client’s specific technical requirements.
Robotization and handling
In the field of robotics, we program units from manufacturers such as KUKA, Fanuc, and ABB, utilizing them for palletizing, depalletizing, and precise part handling tasks. Our completed projects also include solutions based on Epson SCARA robots and Universal Robots collaborative robots, which support operators’ work in picking zones.
Drives and positioning systems
We configure extensive drive systems using components from brands such as SEW or Siemens. Depending on the project’s specifics, we also implement Yaskawa and Lenze drives, and we achieve precise positioning in buffer storages, among other things, thanks to rotary tables from Weiss.
Identification and traceability
We guarantee full traceability at every stage of the process by implementing RFID technologies and vision systems based on DMC codes. In our implementations, we integrate solutions from market leaders such as Balluff, Cognex, Keyence, and Siemens. This allows us to ensure precise supervision over the component from the moment it is received in the warehouse until it is released to the production line.
Vision systems and measurements
For controlling the arrangement of goods and verifying processes, we implement vision systems from brands such as Keyence, Vision Tools, NeuroCheck, Sensopart, or Omron. We also perform verification of load completeness through the integration of weighing systems, using, among others, solutions from Mettler-Toledo or Minibea Intec.
Testing technologies and marking
In our stations, we integrate leak testers from manufacturers such as Bayer, Zeltwagner, or JW Froehlich. For permanent identification of components, we use marking lasers and engraving machines, collaborating with companies such as Trumpf, Borries, and Keyence.
IT integration and digitalization
We connect the hardware layer with superior ERP/MES class systems, integrating solutions such as Aveva or dedicated systems, for example IPM, PRISMA, or ZellSystem. We use modern simulation environments to perform virtual 3D commissioning, which optimizes the implementation process regardless of the equipment brand used.
Do you want to automate storage processes?
Increase throughput and reclaim space with our expertise.
How do we help automate storage processes?
We will guide you through the entire process of transforming your internal logistics – from concept to full system launch. Leveraging our experience in projects for global industry leaders, we can optimize your facility by:
Designing Intelligent Flows
We develop concepts and simulations that eliminate bottlenecks in transport between the warehouse and the production line.
Construction of transport systems
and storage
We are implementing automated high-bay racking, lifts, turners, and extensive roller and belt conveyor lines.
Robotization of in-process logistics
We are launching fully automated palletizing and depalletizing cells, as well as packing stations, replacing manual load handling.
Implementing error-proofing systems (Poka-Yoke)
We develop intelligent workstations that assist operators, guaranteeing 100% accuracy in component picking and assembly.
Integration with higher-level systems
We integrate the hardware layer with WMS/ERP/MES host systems, ensuring full real-time visibility of inventory levels.
Commissioning and support engineering
We provide full programming, testing, and professional team training in operating new systems.
For which industries is the automation of storage processes crucial and what benefits does it bring?
Automotive parts distribution
Automotive parts distribution is a daily struggle with thousands of product indexes. Storage automation organizes this process, transforming the chaos of a huge number of SKUs into a precise and efficient system. The use of vertical lift modules or carousel racks reduces access time to parts to a minimum, which directly translates into faster repairs in service centers and shorter vehicle downtimes. These systems allow for space recovery even with an extremely varied assortment, while eliminating picking errors. Thanks to this, logistics becomes predictable, error-free, and fully ready for the industry’s high pace of work.
Food and Beverage Industry
In the food industry, the fight for freshness is a race against time. Storage process automation takes on the role of quality guarantor here, rigorously overseeing product rotation according to FIFO and FEFO principles. Automated warehouses eliminate human errors when issuing batches, which in the fresh food sector directly translates into fewer losses and consumer safety. Thanks to unmanned transport systems, maintaining the continuity of the cold chain and the highest hygiene standards becomes a standard, not a challenge. This is technology that accelerates product rotation and protects the brand from the risk of contamination or errors in expiration dates.
Pharmaceutical industry
Automation of storage in pharmacy guarantees safety and full compliance with GMP standards. Intelligent systems take over supervision of the most sensitive parameters – from rigorous temperature and humidity control, to precise tracking of every drug batch. Thanks to full traceability and automatic verification of expiry dates, the risk of picking errors is eliminated. This solution not only optimizes inventory, but above all protects the manufacturer’s reputation, safeguarding valuable products from damage, unauthorized access, or errors in stock rotation.
Production plants
In modern production, storage automation is the foundation of the Just-In-Time strategy, eliminating the threat of costly downtime. Intelligent systems, such as racks with stacker cranes, take full control over the flow of components, semi-finished products, and finished goods, removing bottlenecks between assembly stages. Thanks to direct integration with ERP and MES systems, every product batch is monitored in real-time, which guarantees the highest quality and order in the supply chain. This is a solution that transforms the warehouse into an efficient link in the process, improving work ergonomics and genuinely lowering the operational costs of the entire plant.
E-commerce logistics centers
In e-commerce centers, storage automation is the foundation of speed and precision, which determine market advantage. With a gigantic volume of shipments, solutions such as autonomous robots or “goods-to-person” systems maximize picking efficiency and optimize space utilization. Automation minimizes package preparation time and eliminates order errors, while also supporting efficient returns management. This translates into a measurable reduction in operational costs and allows for maintaining the highest service standards even during sales peaks.
Heavy and machinery industry
In heavy industry, storage automation is the foundation for the smooth assembly of large-sized components. Automatic systems guarantee the safe storage of details such as castings, engine blocks, or steel structures, ensuring instant access to them exactly when needed. The use of specialized elevators, turntables, and suspension systems makes the flow of materials between the hall floors and the production line an unattended process. Such a solution eliminates the risk of accidents during the transport of heavy loads and downtime during final assembly, which directly increases the efficiency of the entire plant.
What will you gain thanks to professional automation of storage processes?
You will make maximum use of the volume.
You will increase storage density, recovering valuable space without the need to expand the hall.
You will eliminate human errors
Vision systems and Poka-Yoke standards will ensure 100% accuracy in picking and dispatching goods.
You will ensure 24/7 continuity
Your logistics will operate at maximum efficiency around the clock, regardless of staff availability.
You will drastically shorten the cycle time
Automated conveyors, lifts, and turntables will speed up the flow of components between the warehouse and the production line.
You will reduce operational costs
Optimized energy consumption, reduced product damage, and lower labor costs will translate into a rapid return on investment.
You will gain full control
Thanks to integration with PLC controllers and IT systems, you will have real-time visibility of every goods movement.
FAQ – Frequently Asked Questions
What higher-level systems do your solutions integrate with?
We fully integrate our control systems with the client’s IT layer. We integrate devices directly with ERP class systems (e.g., SAP), MES, and WMS, which ensures two-way data exchange regarding inventory levels and batches in real-time.
Does your company implement automation for storing goods with non-standard dimensions?
Yes. We offer storage process automation services for goods of various sizes. We design dedicated transport and positioning systems (lifts, turntables, suspension systems) capable of safely handling heavy parts, such as castings or engine blocks.
How do your automatic systems handle expiry date control?
Our control algorithms rigorously monitor product rotation. Thanks to the integration of vision systems and DMC code scanners, our system is able to automatically block the release of batches not compliant with the expiry date, eliminating errors and product losses.
Does the automation of storage processes pay off with a smaller volume of goods?
Yes, because we design our solutions with scalability in mind. Automation is not only about handling a large number of packages, but primarily about eliminating errors and saving space. Even with smaller volumes, the systems we implement allow for precise inventory management and free employees from repetitive, time-consuming tasks.
What specific savings does the automation of storage processes generate?
Automatic storage systems significantly reduce operating costs by reducing picking errors thanks to Poka-Yoke standards, lower energy consumption compared to a fleet of forklifts, and almost complete elimination of goods damage. Additionally, automation ensures 24/7 continuous operation, which allows for faster inventory turnover and better capital utilization.
How do you achieve precise positioning in buffer warehouses?
We base movement precision on advanced Motion Control systems. For this, we use, among others, Siemens Sinamics or Yaskawa servodrives, and for rotary operations – Weiss tables. This configuration allows us to position loads with sub-millimeter accuracy, which is crucial for automatic part retrieval by robots.
Does the automation of storage processes offered by you include vision systems for quality control?
Yes, the integration of vision systems from brands such as Keyence, Cognex or Vision Tools is standard practice for us. We use them to verify product placement, read DMC codes, and check load completeness. Thanks to this, our company delivers solutions that not only transport goods, but also continuously monitor their correctness.
How do you address the issue of security in your automated storage systems?
We integrate advanced Safety controllers (e.g., Siemens F-CPU) and safety light curtains and scanners from reputable suppliers. Our systems undergo rigorous tests and simulations to ensure full personnel protection while maintaining maximum machine efficiency.
Can your company implement a project based on specific brands of components that we already use in our facility?
Yes, our solutions feature hardware flexibility. While we typically rely on solutions from leaders such as Siemens or SEW, we integrate systems based on components from manufacturers specified in the Client’s plant standards. We adapt the control logic and electrical designs so that new systems are fully consistent with the current machinery and spare parts warehouse.
Contact us – we will reply within 24h!
Do you have questions about storage process automation? Fill out the contact form, and our team will contact you within 24 hours – by phone or email.
During the conversation or correspondence, we will jointly determine the scope of works and services you are interested in. Next, we will conduct an internal analysis of your inquiry to prepare the best possible solution.
Within a maximum of 5 business days, we will get back to you with information on the next steps.
Take a step towards modern automation – fill out the form now!
