How Rhenus Reached Record-High Throughput with AutoStore

One of the Fastest-Performing AutoStore Systems in the World

Rhenus has achieved a remarkable leap in efficiency and operational performance with AutoStore, implementing one of the highest-throughput systems ever built worldwide. Developed in collaboration with AutoStore partner Kardex, this large-scale installation powers Thalia, the leading omni-channel bookseller in Germany, Austria, and Switzerland. The result is an automated warehouse that combines extraordinary speed, precision, and scalability, setting a new benchmark for logistics excellence.

About Rhenus and Thalia

Rhenus is a leading global logistics provider operating across 1,330 sites in more than 70 countries, with extensive experience in warehousing and managing complex supply chains. For over 20 years, Rhenus has been the trusted logistics partner of Thalia, managing distribution to hundreds of physical stores and a rapidly growing e-commerce network.

As Thalia’s order volumes expanded, so did the demand for faster fulfillment and higher flexibility. Together with AutoStore and Kardex, Rhenus designed and implemented an automation solution that could scale dynamically while maintaining exceptional accuracy and reliability.

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The Challenge: Keeping Up With Growing Demand

Rhenus’ manual processes were reaching their limits. Serving hundreds of stores while handling surging e-commerce orders required a system that could deliver high throughput, space efficiency, and process reliability, all within existing warehouse constraints.

The company needed a solution that would:

• Increase order accuracy and fulfillment speed
• Reduce processing times
• Optimize available space
• Simplify training and onboarding for seasonal staff

Rhenus also needed flexibility to meet future growth and changing demand patterns across Thalia’s omni-channel operations.

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The Solution: AutoStore’s Automated Warehousing

To meet these goals, Rhenus implemented an AutoStore automated storage and retrieval system, empowered by Kardex.

The system occupies a footprint of just 8,000 m² (86,112 ft²) and includes:

• 530 R5 Robots
• 94 CarouselPorts (workstations)
• 240,000 storage Bins
• 2.5 km conveyor system

All components are seamlessly integrated with Rhenus’s warehouse management system. Within this compact space, the AutoStore Grid achieves an impressive 13,100 Bin presentations per hour, making it one of the highest-throughput AutoStore systems ever built.

Goods are stored in stacked Bins within an aluminum framework called the Grid, where Robots move across the top, retrieving items as needed and delivering them to workstations for picking or replenishment. The system’s design ensures fast, continuous operations with minimal manual handling, combining speed, reliability, and scalability.

Key Benefits: Productivity, Speed, and Scalability

The AutoStore system transformed operations at Rhenus, enabling 100% productivity growth and 75% faster training for new employees. Without expanding its workforce or warehouse footprint, Rhenus can now process significantly higher order volumes with exceptional accuracy and consistency.

Key Benefits

• 13,100 bin presentations per hour, among the highest globally
• 100% increase in productivity enabling higher order volumes
• 75% faster training for new staff
• Space optimization with 240,000 Bins in only 8,000 m²
• Reduced errors through automated processes
• Scalable system design ready for future expansion

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Set For Growth

The Rhenus project reflects a strong partnership between Rhenus, Kardex, Thalia, and AutoStore, bringing together logistics expertise and cutting-edge automation. The result is a solution that meets today’s high demands while giving Rhenus the flexibility to grow for years to come.

Project Specifications

• Implementation type: Brownfield
• Robots: 530 R5 Robots, 1 Bin ResQ Robot
• Workstations (Ports): 94 CarouselPorts
• Bins: 240,000 Bins
• Integrated technology: KCC Software; IPA Picking Assistant; 2.5km Conveyor System‍
• Integration partner: Kardex