Scalable Automation at Your Own Pace: How RackBot Systems Facilitate the Implementation of Modern Warehouse Logistics

In many companies, automation is still viewed as a complex and costly major project – one that is primarily reserved for international and very large corporations. But this view is outdated. With intelligent, flexible solutions, SSI SCHAEFER can enable even small and medium-sized companies to effectively implement automated logistics processes. The flexible RackBot Systems enable rapid, economical and scalable automation.

 

Goods-to-Person: Increased Efficiency, Storage Density, and Scalability

The RackBot Systems from SSI SCHAEFER belong to the new generation of autonomous goods-to-person picking. With their modular nature, they can be easily integrated into existing warehouse structures and IT environments, without the need for major modifications and with minimum impact on live operations.

Benefits at a glance:

• up to 130% greater storage density: Greater space utilization than manual storage through the utilization of vertical space (more levels, access to greater heights) and dynamic slotting logic for denser storage.

  

• automated transport: The deployed bots deliver goods to the workstations in an optimized, sequenced flow.

• more efficient picking: Including returns handling through direct reintegration into storage, minimizing errors, and meeting the highest quality standards.

• rapid new availability of articles and more reliable lead times

IT integration:

Integration takes place via a WCS in the existing WMS (e.g. SAP EWM or the intralogistics software WAMAS). Stock management is still via bins in the host system. Wave/batch releases serve as performance levers: The WMS enables the tactical release of orders; the WCS ensures optimum processing and sequencing.

Maximum Flexibility: Solutions for Every Warehouse Structure and Company Size

A key advantage of the RackBot system is its high degree of customizability. Companies can adjust the system to suit their particular requirements. From load carrier sizes to weight classes to specific picking processes.

Four system variants enable applications for every scenario:

• RackBot System ECO – standardized goods-to-person for a rapid, cost-efficient start. 

• RackBot System COMPACT – increased storage capacity with layout and process logic (consolidated occupancy, intelligent navigation).

• RackBot System FLEX – mixed operation of different loading units (bins/cartons/pallets) using transfer points; ideal for mixed product ranges and omnichannel requirements.

• RackBot System ELEVATE – greater performance and density ranges with additional robotics levels (multi-storey supply, high pick rates).

All systems support load carriers of up to 30 kg (bins, cartons) and can be combined as required.

Rapid Implementation and Economic Benefits

Another advantage: integration takes just 6 to 8 months. This makes RackBot Systems not only a future-proof technology, but also an investment that can be realized quickly.

Scaling logic

Throughput increases with the number of robots (transport/sequencing) and workstations (pick/pack) – the rack remains static. Performance adjustments are possible without layout changes and can be made alongside current operations (e.g. additional bots, more stations, adjusted shift models). This allows for peak scaling without oversizing the infrastructure.

Process logic

Goods-in → robot-assisted storage → sequenced staging → pick → restorage → consolidation/shipping.

Cost-effectiveness:

• Reduced walking distances with goods‑to‑person.

• Decoupling picking performance from the individual: robotics delivers consistent performance, while employees pick ergonomically.

• Scalable in peak times using additional bots/stations, without the need for major structural changes.

The example of Desigual shows how impressive the benefits are in practice. With the help of 25 RackBots, the fashion group:

• Increased its handling capacity to 30,000 units per day.

• Implemented the go-live in just seven months after planning started.

• Introduced the system in an existing warehouse.

Proof of just how cost-effective and efficient mobile robotics can be.

Usage scenarios across all sectors

• E‑Commerce: single-item and small batch picking, rapid restocking

• Omnichannel fulfillment: store‑ and online‑ delivery in one single, integrated system 

• 3PL service providers: flexible processing of changing product ranges without rigid layouts

• Returns processing: direct restorage for maximum stock availability

Automation without Obstacles – Getting Started Successfully With RackBot Systems

RackBot Systems offers a simple and secure route into automation for companies of any size. They enable rapid digitalization of initial processes and noticeable stabilization of existing processes. SSI SCHAEFER takes on complete responsibility for the entire process, from solution design to IT Integration (WCS/WMS) to safety concepts, implementation, and service.

If required, RackBot solutions can be seamlessly integrated into existing SSI SCHAEFER systems, for example, connected to conveyor technology, combined with automated guided vehicles (AGVs), or integrated into the WAMAS software environment. A central contact person, a consistent overall concept, and modern technology create an integrated, scalable solution that grows with the company over the long term.

 

About the authors:

Markus Külken

Markus Külken directs the Partner Business at SSI SCHAEFER. In this role, he controls the strategic selection, qualification and governance of all technology partnerships – from the initial assessment and business case development and contract drafting to integration into the portfolio, processes and global sales organization. This includes both the technical and the commercial integration of new partner solutions and their scaling in international customer projects. Under his direction, partners are on-boarded in a structured manner, incorporated into comparable existing system architectures and used as drivers for the further development of the solution portfolio.

 

Johannes Möhrlein

Johannes Möhrlein leads the Partner Empowerment Team within Partner Business at SSI SCHAEFER. He and his team offer customers around the world innovative system solutions from partnerships with other companies. At the same time, he ensures that colleagues in sales are fully prepared to successfully sell these new products. These partnerships are an important way to ensure that customers can always access the best solution for their specific projects.