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Warehouse Automation Systems: Definition, Benefits & Solutions [2021]

Written on
January 27, 2021
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Warehouse Automation Systems 2021


Warehouse automation refers to the use of advanced technology in the packing and distribution of products. Automation is a way of optimizing one's daily activities as far as logistical handling of products is concerned. Some of the definitions to help you understand warehouse automation systems include;

  • The system refers to a storage and retrieval system that optimizes its operations using sophisticated machinery and technology.
  • It can also be explained as advanced technology such as artificial intelligence and robotics to support the human workforce in logistics delivery and expectations.
  • It is the use of computerized systems to execute decisions such as picking products, labeling, stacking, and placement of orders in a warehouse to ensure quick and efficient service.
  • It can also be defined as using automated systems in replacing the human workforce, ensuring the limited occurrence of errors while upholding quality service.

The above indicate that automation of a warehouse relies heavily on the use of advanced technology. This automation is divided into three different levels depending on the amount of technical advancement included. The categories include;

Low-level automation

The low-level automation is also referred to as the manual stage of warehouse automation. It mainly explains the traditional form of the warehouse system. This level includes limited use of technology and relies heavily on the workforce to handle regular day to day packing and delivery of products.

Use of warehouse management system for decision making

Larger warehouses use this second category to help them keep up with the increased supply. This category involves tech use in decision-making and is vital in supporting the supply chain and meeting demand by handling the management system. It mainly allocates tasks to employees and carries out minor decision making such as the use of scanners to keep inventories updated.

Advanced automation

Advanced automation is used to run highly specialized warehouses. It ensures deadlines are met and works to push customer satisfaction. Advanced automation involves using advanced technology robotics and different automation solutions to replace the human workforce, increasing the amount of work a warehouse can do. This level focuses not only on delivery but also on storage use, decision making, packing, and labeling products awaiting shipment.

From the above categories, it is evident that identifying the different tech systems is essential to ensure automation success. Some of the tech ideas to take into consideration to help you realize your automation goals include;

Use of robotics

Robotics enables you to use robots to fasten your process and minimizes errors helping you keep your customers happy.

Use of RFID tagging

RFID tagging provides you with distinct identification of products easing the packaging and shipment process, ensuring you are on time.

Cloud computing and storage

Managing a warehouse means you need enough storage to store customers' information; thus, cloud computing enables you to go paperless enhancing customer service.

EDI communications

Warehouses have different systems that require communication; thus, having a functional EDI communication system is essential to enable you to carry out seamless data exchange from one point to another.

On-demand warehousing

Using technology to help you carry out on-demand warehousing means you can keep up with demand, especially during the holiday season.

Benefits of warehouse automation systems

1. Reduction of cost

The automation solutions can handle more work than an average person can, meaning you do not have to pay overtime. This factor ensures that you are not spending more during the peak season to ensure deliveries are done quickly. Observing this helps in reducing your overall expenditure. Most of the automation solutions can do the job of almost ten people reducing the amount you have to spend to pay a person.

2. Fast and efficient delivery

The use of technology enhances the number of orders you can take and increases the number of customers a warehouse can handle. This factor means that an automated warehouse can deliver products in a shorter time or carry out overnight deliveries, making them reliable and efficient, especially during holiday seasons when orders are more.

3. Minimizes errors

The use of automated warehouses translates to the reduction of errors during the different product cycles. Machines are not likely to get tried and make errors out of fatigue. Even the most accurate and diligent human being is likely to make more errors than robots or machines. Thus, warehouses that use automated systems are likely to get client details correctly and ensure proper packaging minimizing errors that may be costly to the business.

4. Increases speed

The automation increases speed as far as product retrieval and dispatching are concerned. It uses different technologies to identify the correct product faster and enables you to capture the order correctly. It also helps in reducing the amount of time you require to pack the product for shipment. It also enables you to provide same-day deliveries to a broader radius due to its ability to quickly locate and dispatch orders.

5. Maximizes space

Space is vital in a warehouse; thus, automation of the system enables you to fully maximize your warehouse space by providing a wide variety of options. It maximizes the use of vertical space to enable you to use your warehouse space properly. It also helps you go paperless and uses robots to reach areas that human beings may struggle to reach, enabling better use of available space. You are thus, able to grow your business without having to add a physical warehouse.

6. Helps you to keep track of your orders

The use of various automation services enables you to properly keep track of goods in and out of the warehouse. You can keep track of how many products leave the warehouse daily and enable you to determine your peak times. This information is vital to ensure you are adequately prepared to handle customer demands.

It also ensures you can keep track of how many goods you issue, making your auditing process efficient and transparent. It is also vital to note that proper inventory keeping is essential in helping you know when to upscale and when to reduce stocking levels. You also get an opportunity to store customer information, ensuring you offer them individualized service.

Warehouse Automation Solutions

Warehouse automation systems solutions refer to the different tools used to automate warehouses. This section enables you to identify some of the warehouse automation systems and their role in automating a warehouse.

Modular Conveyor Platform (MCP)

The Modular Conveyor Platform (MCP) is designed to enable easy and quick installation. The tool is designed with unique features that make it flexible and easy to install, reducing the amount of time taken to assemble it in the warehouse. It also has refined technical details that ensure easy transportation of materials

Modular Conveyor Platform (MCP)

Its maintenance level is low, and it can easily be adjusted, making it reliable for a growing warehouse. The modular conveyor platform is among the most versatile in the market due to its production focusing on improving warehouse services by increasing throughput. The Modular Conveyor Platform MCP offers cost and energy efficiency and allows you to carry out vital sorting of elements such as diverts stops, lifts and transfers. It uses belts and rollers to carry out conveying functions vital in sorting and enhancing overall performance.

Modular pallet conveyor platform (MPP)

A Modular Pallet Conveyor Platform (MPP) is essential not only in allowing you to plan storage but also to ensure ease in picking products. The model focuses on increased capacity and shortening of retrieval time by having a fully optimized storage plan that ensures products are stored in a way that facilitates fast retrieval.

Modular pallet conveyor platform (MPP)

It also focuses on shortening the production and storage area of companies allowing you to reduce the overall cost of inside transportation and workforce required for retrieval. It is specially engineered for easy installation and provides avenues to ensure a faster return on investment due to its flexible design that allows for smooth operation in a warehouse. The design also ensures proper usage of space, helping you cut down on cost. The Modular Pallet Conveyor Platform MPP offers solutions for various standard pallet types giving you a variety to choose what works best for your warehouse.

Carton Flow Shelves

The use of Carton Flow Shelves enables you to save time and space. This solution can easily be installed or integrated into existing warehouse design to provide fast and efficient pickup. The carton shelves design enables you to pick more products from one rack and is ideal for lightweight products.

Carton Flow Shelves

It cuts down on time spent due to its ability to deliver more products simultaneously. Its design is placed so that one side acts as a loading part. In contrast, the other side delivers the required goods, making it ideal for peak season delivery by ensuring efficiency and reducing the possibility of errors.


Sorters use a conveyor belt specially designed to carry goods and gently remove them once it reaches its desired point. Sorters are highly efficient and eliminate walking time by bringing a product from storage to the desired location. It also requires minimal maintenance.


Its open structure makes it ideal for the transportation of products of different sizes and weights, making it versatile for warehouses that deal in a wide variety of products. Its maintenance cost is low, enabling you to cut down on overall cost.

Pallet flow

The Pallet Flow is ideal for maximizing space due to its design that eliminates aisles' presence. The design is ideal as it encourages minimal handling of goods, reducing the number of people you require to work in the warehouse. It is highly optimized, making it one of the most compact type of goods storage that requires less handling while upholding picking accuracy.

Pallet flow

It also uses the first in, first out algorithm ensuring date sensitivity and managing warehouse storage by ensuring you do not have products in the store whose time may be running out. Its compact nature ensures the safe flow of goods and eliminates chances of loss due to expired goods.

At Industrial Engineering Solutions, we also provide Automated Storage and Retrieval Systems ASRS which aid in the storage and retrieval of products and inventory whenever they are needed. These automates storage and retrieval systems include the following:

Paternoster Vertical Carousel

The Paternoster Vertical Carousel requires up to 75% less floor space than traditional warehouse solutions making it ideal for large warehouses. It works by automating the picking process eliminating errors made during the process. The paternoster uses computer technology to identify the shortest route to take products to the operator.

Paternoster Vertical Carousel

It also allows for different portioning and is ideal for storage and dispatching different types and sizes of goods. It allows for the setup of retrieval points on different floors and protects products from dust and damage, ensuring overall customer satisfaction.

Tornado Automated Storage System

The Tornado Automated Storage System is a computer-controlled system that uses vertical space to enhance storage options. It is swift, making it ideal for reducing walking and pickup time. The Tornado ensures paperless ordering of products saving space and time required for retrieval of products.

Tornado Automated Storage System

The system uses two tray location models to eliminate the need for an inner door and increase its speed. It is specially equipped to handle goods of different heights, allowing you to change the tray height accordingly. It is ideal for the production line due to its ability to handle different sizes of products.

The Horizontal Carousel (HOCA)

HOCA uses a sophisticated computer system to enable it to carry out its functions. This system is designed to enhance the quick retrieval of products using a computer system that enables you to pick a product from the system and having it delivered. The unique thing about this automation is that it can simultaneously pinpoint many orders, bringing each to the pickup point with accuracy.

The Horizontal Carousel (HOCA)

The system makes use of horizontal space in places with limited overhead space making it ideal for low ceiling head rooms. The system also reduces walking and waiting time, significantly impacting overall performance.

Contact Us for More Information

The installation and use of warehouse automation solutions require proper research and expertise to ensure you do it correctly. Our Experts will also analyze your warehouse needs and help you pick the type of warehouse solution that meets your needs and sets your business up for success. 

To learn more about Warehouse Automation Systems, simply contact us at +1 (844) 909-0437 today. You may also email the company at or via this form.


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