When Available Area Becomes a Limiter: How Modular Robotics Can Future-Proof Your Existing Warehouses

The first part of our blog series focused on a step-by-step adoption of automation. But automation alone does not solve every problem, especially when available space becomes the limiting factor.

Small and medium-sized enterprises, in particular, face the challenge of managing increasing order volumes and new business requirements with their existing warehouse structures. Additional halls and extensive conversions are often costly and offer little flexibility. Therefore, solutions are needed that maximize use of the existing warehouse space and can also grow along with the company, without restricting business operations.

 

Modular system design as the basis for flexible expansion

This is exactly where RackBot Systems from SSI SCHAEFER come in. They are based on a combination of standard static shelving systems and autonomous mobile robots which can be easily implemented in existing warehouses without the need for complex structural modifications. Further shelving and robots can be added independently of each other and thus adapted to changing conditions. This can also be done without shutting down the system. This modular approach allows the targeted development and optimal use of existing warehouse space.

Another advantage: Even if the structure of the aisles cannot be changed, the overall layout remains flexible. Flexible designs, such as L‑shaped configurations or those adapted to irregular building structures, enable a seamless integration even in challenging, existing buildings.

Maximum space utilization through height, depth, and intelligent occupancy

RackBot Systems make consistent use of vertical storage space – up to 12 meters in storage height can be utilized. Furthermore, double or triple-depth storage produces a very compact storage system with a high degree of space utilization.

In specific applications, up to 43 bins can be stored per square meter. 

At the same time the system remains flexible:

• High performance even when product demand patterns change

• Different bin sizes

• Cartons (ready for immediate handling, without repacking)

• Trays

It is generally possible to mix different loading units within a single system. Bins can also be removed directly from the system and processed further – a clear advantage for end-to-end processes without additional buffer stages.

Full-roaming robotics instead of rigid performance limits

A key distinguishing feature, compared to traditional, aisle-based automation solutions, is the full-roaming capability of RackBot Systems. Every bot has access to every bin throughout the entire warehouse. This eliminates the coupling between aisle throughput and storage capacity issues that are common in conventional systems.

The advantages are clear:

• Shorter access times, even with high system utilization

• Stable throughput, even with highly fluctuating load profiles

• High future-proofing in the event of changes to the product range, profile or processes

Since RackBot Systems do not rely on a rigid ABC classification, performance remains constant even when item profiles, turnover rates or order structures change. Unlike solutions that are heavily zone-dependent, this architecture enables consistently flexible, resilient process performance.

Intelligent sequencing – directly within the system

Order sequencing is handled intelligently by the bots themselves. Within an order, load carriers are delivered to work stations strictly in the required sequence, without the need for additional conveying systems.

This not only increases process reliability but also significantly shortens cycle times.

Urgent orders can be processed particularly quickly: In performance-optimized configurations (e.g. RackBot System ELEVATE), a required bin is made available at the work station within two minutes.

Flexible capacity enhancement without downtime

RackBot Systems can be expanded incrementally and during ongoing operations. Performance is achieved not through structural changes, but through:

• Additional robots

• Additional work stations

• Adapted operating strategies

The shelving system remains static and so layout changes are not required. This allows companies to gradually adapt their capacity to meet growing demands without having to design their infrastructure from scratch to meet future targets. In turn, this provides investment security and represents a decisive economic advantage.

The success story of Desigual demonstrates how this concept delivers in practice: 

With 25 RackBots, the fashion group was able to significantly improve its warehouse performance. It achieved a throughput of up to 650 cartons per hour and 150,000 units per week in a two-shift operation. What is more, the system was implemented in just seven months, from planning to go‑live. The key to this performance gain is the combination of efficient space utilization, intelligent process logic, and the ability to further develop existing structures in a targeted manner.

About the authors:

Markus Külken

Markus Külken is responsible for SSI SCHAEFER´s entire partner business. In this role, he oversees the strategic selection, qualification, and governance of all technology partnerships – from the initial evaluation, the business case and contract drafting through to integration into the portfolio, processes, and global sales organization. This includes both the technical and commercial integration of new partner solutions, and their scaling in international client projects. Under his leadership, partners are onboarded in a structured manner, integrated into existing system architectures to ensure interoperability, and deployed as drivers for the further development of the solution portfolio.

Johannes Möhrlein

Johannes Möhrlein leads the Partner Empowerment Team as part of the partner business at SSI SCHAEFER. He and his team offer customers around the world innovative system solutions borne from partnerships with other companies. At the same time, he ensures that his colleagues in Sales are ideally prepared to successfully market these new products. These partnerships are an important part of our ability to consistently offer customers the best solution for their specific project.