AutoStore

What is AutoStore?

AutoStore refers to a cube-storage-based warehousing system in which plastic bins are stacked directly on top of one another within a dense aluminum or steel grid. Autonomous robots travel across the surface of this grid, lifting individual bins from the stack, transporting them across the grid, and delivering them to designated ports. At these ports, employees or robotic arms pick the required items. The underlying principle — goods travel to the person, not the other way around — follows the Goods-to-Person approach.

The technology was developed in Norway and is patented as a system concept. Several system integrators worldwide are authorized to implement AutoStore installations. Organizations planning an AutoStore system are not simply purchasing hardware — they are committing to a proprietary ecosystem with specific software, maintenance, and expansion agreements. This should be explicitly evaluated during vendor selection and when building the business case.

How does AutoStore work in practice?

The grid forms the physical structure of the warehouse. Bins are stacked up to several meters deep; a robot may first need to temporarily relocate bins sitting above the target bin (a process known as digging) before it can reach the required bin. The frequency of this repositioning depends on the storage depth, the range of SKUs, and the distribution of access frequencies. A well-designed slotting strategy — such as ABC analysis of items — can significantly reduce unnecessary robot movements.

The overall system throughput is determined primarily by three factors: the number and speed of robots, the number of picking ports, and the efficiency of the control software in scheduling travel routes and digging operations. Because robots operate independently of one another, throughput can be incrementally increased by adding further robots — a frequently cited scalability advantage. However, physical limits apply: beyond a certain robot density on the grid, waiting times increase due to intersection management.

Picking at the ports can be performed manually, semi-automatically using pick-by-light, or fully automatically using robotic arms. The choice of port technology has a significant impact on both capital investment and achievable throughput.

What should you consider when making a selection?

• Space efficiency vs. throughput: AutoStore achieves very high storage density because no aisles are required. However, for very high throughput requirements with a broad product range, the number of ports and the robot fleet must be carefully sized.
• Bin compatibility: Only goods that fit within the standardized bins can be stored. Bulky, heavy, or temperature-sensitive items require separate solutions or specialized bin variants.
• Vendor lock-in: The system is proprietary. Maintenance, software updates, and expansions are handled exclusively through authorized partners. Long-term contractual terms should be reviewed thoroughly before signing.
• Availability and redundancy: Since all robots share the same grid, the system remains operational if individual robots fail — albeit at reduced throughput. This is a frequently cited positive feature. A failure of the central control software, however, is a critical risk.
• Scalability: The grid can be expanded in a modular fashion, provided the available floor space and structural load capacity allow for it. Nevertheless, every expansion requires advance planning and system integration.