Automation & Sustainability in Peak Season
We recognize that the logistics sector plays an active role in reducing emissions, conserving resources, and operating more efficiently. As supply chains grow in complexity and scale, automation and robotics are becoming vital tools for building greener logistics. From reducing energy use to enabling paperless processes, technologies are helping us and our clients to create more sustainable operations.
Automation: A Foundation for Greener Supply Chains
Logistics centers are traditionally energy-intensive, labor-heavy environments. They consume large amounts of electricity, rely heavily on physical paperwork, and generate packaging waste and transport emissions. But with automation, we’re rethinking these dynamics. Our facilities integrate intelligent systems that automate repetitive tasks, minimize manual errors, and optimize space and energy usage. For example, Stretch, the autonomous case-handling robot from Boston Dynamics, is capable of unloading thousands of packages without human intervention. Its precision and speed reduce idle times and eliminate the need for energy-intensive conveyor installations at loading bays.
At the same time, we are transforming fulfillment accuracy by using robotic picking solutions like our robot Dora, provided by Nomagic. Dora uses AI to steer its robotic arm and can pick and place items directly into shipping boxes or insert returns into the AutoStore system. In our use cases, this not only improves speed but also significantly reduces picking errors. This cuts down the number of returns, associated repackaging, and unnecessary shipping emissions.
Made by Arvato: Leleka in Action
At our Hanover site, we’ve taken automation a step further with the deployment of our own robotic arm Leleka. We tailored this custom-built solution to the specific needs of our operations and use it in a high-volume logistics environment. Speed, consistency, and sustainability play an essential role here. Leleka is designed to operate energy-efficiently, work seamlessly alongside human colleagues, and adapt to different picking and packing scenarios. As a result, it helps us increase output while lowering the environmental cost per parcel handled. The system also feeds real-time data into our digital logistics platforms — enabling smart decisions on stock placement, routing, and resource allocation.
From Paperwork to Paperless: Automation & Digitization Go Hand in Hand
Sustainability isn’t just about physical movement — it’s also about information flow. That’s why automation at Arvato is closely tied to digitization. As we automate operational processes, we’re also eliminating manual documentation and switching to fully paperless workflows. From inbound registration and inventory control to customs documentation and end customer documents, our systems generate, manage, and transmit all data digitally. This not only saves tons of paper annually but also reduces the risk of error and accelerates the flow of goods through the supply chain. In a major healthcare project, we digitized the entire warehouse documentation process, leading to a 70% reduction in paper usage while improving traceability and compliance. By digitizing our german consumer products operations, we saved 92 tons of paper in 2024 in total. With each paperless operation, we make our logistics not only faster — but also cleaner.
Energy Optimization in Robotic Warehouses
Another advantage of automation is the ability to control and optimize energy usage at a granular level. Robots like Stretch or AMRs (Autonomous Mobile Robots) can operate in low-light environments. This allows us to reduce lighting to minimum levels during nighttime operations. Unlike human teams, these systems don’t require heated break rooms or fully lit aisles — helping us lower overall HVAC and lighting energy consumption. Moreover, our intelligent warehouse control systems monitor energy consumption in real time, allowing us to dynamically switch off zones, put machines into standby, or reroute tasks to more efficient areas. Combined with renewable energy sources at many of our sites, these optimizations support our ongoing CO₂ reduction strategy.
Less Waste, Better Packaging
Automation also improves sustainability by addressing packaging waste. We’ve deployed automated packaging lines that right-size each shipment. Items are measured and packed into custom-fit cartons — eliminating the need for excessive filler material and maximizing trailer capacity. In some operations, we’ve reduced packaging volume by up to 30% per shipment, which has a direct impact on material savings and transportation emissions. These systems are especially impactful during peak seasons, where the need for efficiency and sustainability is highest.
Scalable and Sustainable
Sustainability isn’t just about machines; it’s about people, too. With our automation strategy we support our teams by relieving them of physically demanding, repetitive tasks, such as lifting, sorting, or walking long distances. This creates healthier workplaces and frees up talent for more value-adding roles, such as quality control, exception handling, or process improvement. We believe that automation should enhance human work, not replace it — and this belief is embedded in every robotic integration we implement.
As we expand automation across our global logistics network, we do so with sustainability at the core of our strategy. Every robot we deploy and every system we digitize is part of a larger mission: to shape supply chains that are not only efficient and resilient — but also responsible. Whether it’s through in-house innovations like Leleka, partnerships with pioneers like Boston Dynamics, or ongoing digital transformation. We create a logistics landscape where automation and sustainability go hand in hand.
