Efficient, Sustainable, Scalable: How AutoStore and PackSize Transform Fulfillment Center Operations
Jack Dean | 15 January 2025
When designing a material handling automation solution, success often comes down to choosing the right pieces that fit together seamlessly. That’s the value of working with an experienced integrator: finding the optimal combination of technologies to meet your operational goals.
The integration of AutoStore and PackSize exemplifies this approach. AutoStore is known for its cutting-edge goods-to-person system, where autonomous robots deliver bins directly to operators, streamlining the picking process and maximizing storage density. PackSize specializes in right-sized packaging, creating custom boxes tailored to each order, reducing excess materials, and eliminating unnecessary void fill.
This pairing creates a smarter, more cohesive process that optimizes labor, space, and materials. It’s a solution that works because when integrated appropriately, the parts work perfectly together. Here’s how this integration can elevate your fulfillment operations.
Boost Order Fulfillment Efficiency with AutoStore and PackSize
Integrating AutoStore and PackSize significantly enhances order fulfillment efficiency by combining two innovative technologies into a streamlined, cohesive solution.
AutoStore’s goods-to-person system dynamically delivers bins directly to operators using autonomous robots. This eliminates the need for manual retrieval, accelerates the fulfillment process, and reduces labor requirements, enabling operators to focus on higher-value tasks. Unlike traditional shuttle-based solutions, AutoStore’s grid-based design minimizes reliance on complex conveyor systems. This reduces system complexity, maintenance needs, and space requirements while improving overall flexibility. This becomes even more appealing in the integration of AutoStore to PackSize as the autonomous robots can be used for buffering of inventory containers to ensure seamless orchestration between the two systems.
PackSize complements this efficiency with its industry-leading right-sizing technology. PackSize eliminates the need for void-fill materials or downstream re-boxing by creating custom boxes tailored to each order's dimensions. These boxes are ready before picking begins, allowing operators to pack products seamlessly in the ideal packaging without additional decision-making.
By integrating AutoStore and PackSize, businesses can create a smarter, more cohesive process that delivers measurable gains in speed, accuracy, and resource efficiency—a combination designed to set a new standard for fulfillment operations.
Reduce Costs with Smarter Fulfillment Solutions
Integrating AutoStore and PackSize provides measurable cost savings across materials, transportation, and space utilization.
PackSize’s right-sizing technology results in up to a 40% reduction in box size, translating into less corrugated material usage and reduced need for void fill. Smaller, more efficient packages also bring substantial savings in transportation costs by optimizing truckload capacity, reducing the number of shipments required, and lowering overall logistics expenses.
Combined with AutoStore’s high-density storage capabilities, businesses can free up valuable warehouse space for other uses, further enhancing cost efficiency.
Key cost-saving benefits:
- Lower material expenses: Right-sized packaging reduces average box sizes, decreasing corrugated and void fill usage.
- Optimized shipping costs: Smaller packages improve truckload utilization and decrease logistics expenses.
- Space savings: High-density storage and reduced box inventories free up valuable operational space.
These financial advantages improve profitability and create a scalable foundation for sustainable growth.
“The average box is 40% too big for its contents.”
Eliminating excess volume would mean 24 million fewer truckloads per year in the U.S.
-DHL, The Logistics Trendsetter
Achieve Sustainability Goals with Smarter Fulfillment
Sustainability is an increasingly important priority for distribution and fulfillment operations, and integrating AutoStore and PackSize delivers measurable environmental benefits while supporting broader corporate sustainability goals.
PackSize’s right-sizing technology minimizes packaging waste at its source, reducing box sizes and void fill. Smaller, more efficient packages also lead to fewer and lighter shipments, directly reducing fuel consumption and carbon emissions. These improvements help businesses lower their carbon footprint and meet environmental benchmarks.
Beyond the operational benefits, this integration enhances customer perception. Appropriately sized, eco-friendly packaging leaves a positive impression, improving the unboxing experience and reinforcing a brand’s commitment to sustainability.
Scalable and Flexible Solution
One of the standout advantages of integrating AutoStore and PackSize is their scalability and adaptability. Whether running a small operation with just a few pick ports or managing a large-scale distribution center with dozens of pick ports, this integration can be customized to fit your needs.
Industries such as retail e-commerce, electronics, pharmaceuticals, and more can benefit from the tailored capabilities of AutoStore and PackSize. These systems handle a wide range of product sizes and order types, making them ideal for businesses with diverse product mixes. Seasonal fluctuations pose no challenge, as the system can scale seamlessly to meet demand while maintaining efficiency and accuracy.
Considerations for Integrating AutoStore and PackSize
Integrating AutoStore and PackSize requires thoughtful planning to ensure the systems work seamlessly together. Accurate product attribute data—such as dimensions and weights—is essential for precise box creation and efficient inventory handling. Effective software orchestration is equally important, with Bastian Solutions’ Exacta intralogistics software facilitating smooth communication between AutoStore and PackSize.
This integration is flexible enough to fit greenfield and brownfield environments, with layouts and configurations customized to suit each facility’s unique needs. Sites with existing AutoStore solutions can also add PackSize to further enhance their operations. Partnering with an experienced material handling automation integrator like Bastian Solutions ensures the implementation process is efficient and tailored to help you maximize the benefits of these technologies.
Unlock the Power of AutoStore and PackSize Material Handling Automation
Integrating AutoStore and PackSize delivers transformative benefits for fulfillment operations, combining efficiency, cost savings, sustainability, and scalability into a seamless solution. By addressing common challenges and optimizing workflows, this pairing provides long-term ROI and positions fulfillment and distribution centers for growth in an increasingly demanding market.
Contact a Bastian Solutions solutions expert today to learn how our expertise can help you design and implement a system tailored to your needs.
Jack is a Solutions Account Executive at Bastian Solutions. In this role, Jack works with customers to design and sell high impact material handling systems focused on increasing fulfillment capacities and decreasing cost, ultimately providing a positive impact to a customer’s bottom line. He joined the company in 2021 following 7 years designing and implementing highly automated fulfillment systems for a leading retailer. Jack holds his degree in Industrial Engineering from the University of Wisconsin - Madison.
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