Maximizing Warehouse Automation: Configuring Your AutoStore System for High-Throughput and Space Savings

Jason Blackney | 29 January 2025

The future of warehousing lies in optimizing every aspect of your operation. The AutoStore system, a cutting-edge automated storage and retrieval solution, offers unmatched efficiency and flexibility. This innovative system uses robots on a grid to store and retrieve bins, maximizing space utilization and dramatically improving pick rates. However, the true success of AutoStore results from the precise configuration that meets your unique high-throughput needs.

At Bastian Solutions, we've engineered and implemented numerous tailored AutoStore systems, directly driving transformative impacts for our clients. This warehouse automation solution turns spatial constraints into advantages, converts idle time into productivity, and evolves with your growing business. Achieving these results demands strategic design and expert configuration for optimal space savings and performance.

Whether you’re new to warehouse automation or enhancing an existing set-up, understanding and optimizing configuration parameters is key to maximizing your AutoStore system investment. Each decision, from grid height and robot deployment to port placement and forecast modes, significantly impacts your warehouse's efficiency, space utilization, and adaptability.

What is AutoStore? The Future of Space-Saving Warehouse Automation

AutoStore is an automated, high-density warehouse storage system redefining inventory management. Its modular design and standard components offer unmatched versatility, allowing it to fit around building columns, fill L-shaped spaces, tunnel over walkways, and deliver to remote access ports across your facility. This adaptability, combined with its ability to maximize storage density, increase picking efficiency, and improve inventory accuracy, makes AutoStore a scalable solution for high-throughput operations that grows with your business.

Configuring Your AutoStore System: 5 Critical Design Parameters for High-Throughput Success

AutoStore's strength lies in its adaptability, but this flexibility also presents a challenge: how do you determine the optimal configuration for your unique needs? The difference between a good AutoStore system and a great one often comes down to fine-tuning five critical design parameters. These parameters don't just affect individual aspects of the system—they interact in complex ways, influencing overall performance, efficiency, and scalability.

Let's explore these key elements and how they work together to create a finely tuned AutoStore solution:

Grid Height

Typically, we maximize vertical space up to 25 feet, accommodating 16 standard or 24 short bins. However, a lower height can sometimes boost speed by reducing digging time. Our team analyzes your needs to determine the ideal height, balancing storage density with retrieval speed.

Footprint

The system's footprint significantly impacts bin travel time to ports. In larger systems, clever port arrangements can drastically reduce travel time. We often implement tunnels in the AutoStore grid, cutting average travel distances and boosting efficiency. These small time savings add up, potentially reducing the number of robots needed and lowering overall costs.

Access Ports

We offer two main port types:

• Carousel ports: Ideal for higher pick rates
• Conveyor ports: Perfect for integrating with existing conveyor systems

We can mix and match port types to suit your needs. For instance, we've designed systems using conveyor ports for sorter feeding and inbound bin replenishment while employing carousel ports for expedited "hot picks."

Robots

More robots generally mean faster picking, but there's a sweet spot. Too many robots can lead to grid congestion, potentially decreasing efficiency. Our computer simulations determine the ideal number of robots for your system, whether you need just a couple for parts delivery or nearly 100 for massive e-commerce operations.

Forecast Mode

This unique AutoStore feature allows robots to pre-position bins for future orders, reducing pick times. We can implement this during off-hours or operational lulls in 24/7 facilities. By strategically using Forecast Mode, we ensure your operators always have a steady work stream, maximizing productivity throughout the day.

We use advanced computer simulations with AutoStore software to model how these factors interact in your environment. This allows us to create a truly optimized system that grows more efficient over time through natural percolation - frequently picked items naturally rise to the top, while less common items settle lower in the grid.

Your Expert AutoStore Integration Partner for Warehouse Automation

As a global AutoStore integrator, Bastian Solutions has seen repeated success with AutoStore installations, both large and small. Our vast network of technology suppliers and in-house manufacturing capabilities allow us to create tailored solutions that precisely fit your high-throughput and space-saving needs.

• Extensive Experience in Warehouse Automation
• Advanced Simulations for Optimal System Performance
• Holistic Approach to High-Throughput Operations
• Ongoing Support for Continuous Optimization

Ready to Transform Your Warehouse with AutoStore?

Visit our AutoStore solutions page to learn more and connect with our team of experts today.

Author: Jason Blackney