High scores for “AutoStore”

Automation is at the heart of modern warehouse logistics: Collaborative robots (cobots), AI-based sorting systems, and automated transport vehicles significantly speed up order processing and minimize the risk of errors. By leveraging these technologies, logistics companies can boost efficiency and cut costs – key factors behind cargo-partner’s decision to introduce the new AutoStore system at its iLogistics Center Vienna.

This extensive project began some time ago. Together with the renowned Fraunhofer Institute, a suitable partner was selected to analyze the logistics processes at the iLogistics Center Vienna and specifically address the growing demand for efficient storage solutions.

Advantages of automated small parts storage

The AutoStore system from HÖRMANN Intralogistics stands out for its flexibility and scalability. Its compact design and seamless box stacking significantly improve warehouse utilization. In addition, AutoStore also allows multiple item types to be stored in one box, further increasing storage capacity. This ensures the optimal use of the mezzanine level in the award-winning timber warehouse.

60 TEUs, lots of grids and even more bins

The new system will be installed in the existing first floor mezzanine, which was specifically designed with the intention of accommodating an automation solution. It consists of a 500 m² aluminum grid measuring 15.4 m x 22.6 m x 6.5 m, providing space for 14,680 containers. When fully completed, the “high-tech cuboid” will be able to accommodate up to 21,030 containers (called “bins”) on 16 levels. This grid system provides a total of 918 grid fields for the bins. To give you a more concrete idea: The AutoStore’s diagonal span measures 28 m. That’s half the size of the Leaning Tower of Pisa (56.4 m high). How convenient that it’s already leaning!

In total, this “kit” of stacked hollow cubes has a volume of 2,263 m³ – roughly equivalent to the capacity of 60 TEU containers. Practically speaking, these 60 containers would be positioned upright, as the length of a “classic” 6-meter container also coincidentally matches the height of the AutoStore.

Cell by cell

The robots are (nearly) tireless sprinters

Of course, the autonomous storage system was primarily designed to enhance goods handling efficiency. Shifting from a “man-to-goods” to a “goods-to-man” model, the robots now bring items directly to the warehouse employees. This significantly boosts processing speed in the truest sense of the word: The seven robots can reach a speed of 3.1 meters per second, covering the entire width of the grid in just seconds.

Incidentally, 3.1 meters per second is equivalent to 11.16 km/h, or to put it more vividly: just a quarter of Usain Bolt’s fabulous world record in the 100-meter sprint. His top speed was 44.72 km/h, or 12.42 m/s. We think that’s quite acceptable, considering the robots’ lack of legs and their weight of 160 kg...

But while track and field athletes need proper nutrition, training and rest, AutoStore robots are much more frugal, requiring fewer breaks and less energy: Even ten AutoStore robots use less energy in operation than a conventional vacuum cleaner. When it comes to keeping the robots running, the formula is simple: 20+4. A typical working day for these little helpers is around 20 hours. Each robot needs at least 4 hours of charging time per day. This is done very cleverly, as they recharge whenever they see an opportunity – for example, during breaks or periods of low activity.

Three carousels and a glass elevator

In addition to the seven robots, the setup includes three “Carousel” and two “Swingport” workstation modules, plus a “BinLift” – a several-meters-high glass elevator that moves the bins between the ground floor and the mezzanine. But the system isn’t about panoramic rides at lofty heights; it’s about supporting the existing workforce. Ergonomic workstations reduce physical strain, and the fact that goods are automatically delivered to employees increases the team’s capacity.

In addition, the AutoStore system can optimize warehouse utilization while addressing the looming skills shortage in the coming years. The space required for small parts storage alone has been reduced by 63%, and the system’s autonomous design enables more employees to handle small parts operations. Thanks to robots and digitalization, even part-time workers and employees without a forklift license can perform these functions. Ultimately, this makes work easier and more ergonomic for cargo-partner employees, allowing them to focus on more sophisticated tasks.

More number crunching

2+1: The aluminum scaffolding was erected within two months. The electrical wiring and technical components such as ports and robots were operational within one month.

0 days of downtime: The AutoStore can be expanded at any time – whether by adding more storage space, deploying additional robots, or adding ports – all without interrupting ongoing operations.

(Almost) 0: In terms of efficiency, the new system will at least halve the throughput time for small parts picking. In addition, image-assisted picking and putaway will reduce the already low error rate – to almost zero!

8,400 tons: The award-winning iLogistics Center Vienna sets new standards not only in logistics, but also in construction: The sustainable timber construction reduced CO₂ emissions by 8,400 tons. With the addition of the AutoStore, this innovative approach continues, for an even more efficient and sustainable warehouse solution.