Storing Ugly Goods Automatically – Answers from the even Webinar with advasolutions

In a nutshell: oversized items, irregular shapes, articles that simply cannot be packed neatly into a standard container. In most warehouses, they end up in a manual process because no automated Solution can handle them reliably. Michael Reimold, Head of Sales Development at advasolutions, demonstrated in the Webinar how carrier-free storage works technically and when it makes sense as a complement to an existing system.

Missed the Webinar? Click here for the full recording.

During the even Webinar with Michael Reimold, it quickly became clear how much interest there is in concrete Solutions for difficult items. We have compiled the most important questions and answers from the live talk here for you.

What exactly are Ugly Goods?

Michael: The term sounds negative, but for us these are not ugly items. We are quite comfortable with them. Ugly Goods, to us, means everything that does not fit into a standard container — for example a 400 x 600 — whether due to oversized dimensions, an irregular shape, or because the item has no container at all. Our latest shuttle generation covers footprints of up to 800 x 600 millimetres at a weight of up to 25 kilograms. And beyond that, we can also store items directly without any load carrier — from a 1.5-kilogram coffee bag to dimensionally stable articles of all kinds of geometries.

Where does the system reach its limits?

Michael: Clearly where items are not dimensionally stable. In the fashion sector, for example, when someone works with polybags — that is where we hit our limits. But wherever items have a defined shape, it does not matter whether the part is square or round. We can grip it perfectly.

How does it work technically? What makes your shuttle different?

Michael: Two things set us apart from conventional captive shuttle systems. First, we have a closed shelf floor that enables direct handling without load carriers. Second, our shuttle handles all movements itself. It climbs via a gear mechanism and travels independently into the respective aisle. We have no conventional lift, which makes the system significantly more scalable. This also allows us to replace conveyor lines and bridge production logistics directly from within the warehouse.

You capture every item at goods receipt. How time-consuming is that really?

Michael: At first glance it sounds time-consuming, but it is actually a huge asset. At goods receipt we capture morphological data, take photos of every item and record its dimensions. Based on this data, the system then dynamically calculates the storage location. There is no predefined slot from the ERP — instead, chaotic storage is managed entirely by the software. What you get in the process is a database that most companies simply do not have: precise master data for each article, including dimensions, weight and photo. This can also be used incidentally for quality control, batch management or serial number tracking.

Which industries is this particularly relevant for?

Michael: Fresh logistics is a clear focus. Wooden crates, fish baskets — you simply cannot repack these into a standard container, and the industry is at the same time extremely labour-intensive and actively looking for automation. Beyond that, we see strong potential in production logistics, the electronics and consumer goods sector, and in pharma. Spare parts and refurbished goods are a good fit, as are shoe boxes — they are always awkward to handle in conventional containers. Classic fashion e-commerce is less of a fit, though there are certainly niches within it. Frozen goods are unfortunately something we cannot cover yet.

When does a carrier-free Solution make sense as a complement to an existing system?

Michael: This is actually one of our most exciting use cases. We are explicitly positioned as an add-on to cube storage systems such as AutoStore as well. Where the article mix allows for it, we take over the portion of the assortment that cannot be cleanly handled within the cube. Beyond that, we can act as a buffer and sequencing system. A pre-picked order from the cube is completed with the Ugly Goods at our station before it goes to despatch. That is a genuine sweet spot for us.

What is the economic sweet spot – from what point does it pay off?

Michael: We are not the system for very high throughput. Our comfort zone is between 500 and 1,500 picks per hour. Anyone who needs to scale beyond that will eventually need so many shuttles that it also becomes unattractive from a cost perspective. The business case works best where part of the assortment remains manual because no other system can handle it — that is precisely the part we can take over, automate and process with significantly fewer FTEs.

Can the system be seen live somewhere?

Michael: Yes. We operate our own warehouse in Nieder-Aula near Bad Hersfeld — right in the heart of Germany, easily accessible from anywhere. Across 18,000 square metres of total space, we run our own system there in full operation. It is the best opportunity to see the complete application live. Anyone interested is welcome to get in touch.

Conclusion: Ugly Goods are not an edge case — they are a systems issue

The Webinar made it clear: items that do not fit into standard containers are not a fringe occurrence in most assortments. They end up in a manual process not because automation is impossible, but simply because most systems cannot accommodate them. advasolutions demonstrates that carrier-free storage not only works technically, but also delivers a clear business case in certain industries and assortments — even more so as a complement to an existing system.

Missed the Webinar?

👉 Here is the full recording.

👉 Here is the even profile of advasolutions.