Pietsch Doubles Throughput with AutoStore

{{quote}}

The Challenge: Outgrowing Space and Manual Operations

The 32,000 m² (344,500 ft²) warehouse had reached its capacity limit. Goods were placed haphazardly, duplicate transports occurred, and proper ABC distribution was no longer possible. Small parts stored on an upper-floor shelving system further slowed operations. Meanwhile, the company was experiencing growing sales volumes, making automation a timely necessity.

The Solution: Automated Warehouse System

Pietsch needed a solution that could optimize space, increase efficiency, and integrate seamlessly with existing operations. AutoStore was chosen for its compact design and scalability. Rather than deploying a stand-alone system, the company opted for a fully integrated automation approach—connecting AutoStore with upstream and downstream technologies such as carton erectors, labelers, carton sealers, and conveyor systems. This integrated solution enabled smooth material flow and order processing from goods receipt to dispatch, all within the same facility footprint. Key features include:

• 65% of order lines now fulfilled via AutoStore
• Throughput doubled using 50% less space
• No increase in headcount
• System implemented during live operations with zero downtime
• Payback period as low as 2.5 years, if business plan will be achieved (current 7.5 years, scalable to <2 years)

‍

Key Benefits: Doubled Throughput in Half the Space

AutoStore allowed Pietsch to:

• Maximize storage density and free up space for growth
• Integrate automation into upstream and downstream processes
• Increase throughput without increasing labor
• Avoid costly facility expansion
• Continue operations uninterrupted during implementation

Key Metrics:

• Current: 3,300 bin presentations/day
• Designed for: 7,800 bin presentations/day
• Scalable to 11,200 bin presentations/day

How the System Works

AutoStore was integrated into the warehouse as the central automation solution, seamlessly connected with upstream and downstream technologies:

• Goods Receipt: 8 workstations, each with 2 Conveyor Ports (single-shift)
• Goods Issue: 4 Carousel Ports (two-shift)
• Automatically erected cartons and reusable containers are delivered to workstations via conveyors
• Outbound cartons sealed, labeled, and transported away through conveyors

Supporting technologies include:

• Carton erector
• Carton sealer
• Labeling system
• Destacker for reusable containers

‍

Project Specifications:

• Installation type: Brownfield
• ‍Robots: 23 AutoStore Robots
• Workstations (Ports): 4 CarouselPorts, 16 ConveyorPorts‍
• Bins: 61,500 Bins
• WMS: ProStore by TEAM GmbH, Paderborn
• Integrated technology: Conveyor system, carton erector, carton sealer, labeling, destacker
• Partner: Empowered by Swisslog

Additional Information:

• The AutoStore system was planned by LOGSOL
• Implementation occurred without any downtime
• Employees were trained and involved from the start, ensuring seamless adoption