Driving Supply Chain Efficiency with Automation & Robotics

How do automation and robotics interact in modern logistics?

Today’s supply chains are expected to be agile, resilient, and sustainable – while maintaining the highest standards of quality and transparency. When used strategically and at scale, warehouse automation solutions – including robots and AI – can effectively address these challenges. Automated systems speed up order processing, reduce human error, and enable round-the-clock operations. AI-driven analytics, meanwhile, help optimize inventory management, predict demand more accurately, and streamline decision-making across the supply chain.

At Arvato, this is already a reality. As a global 3PL fulfillment provider with over 100 locations worldwide, we invest strategically in automation and robotics across the entire material flow – from inbound to outbound, from goods receipt and storage to picking, automated packaging, sorting and shipping. It’s not about using the newest technology for its own sake, but about delivering tailored solutions that meet our clients’ needs while enhancing efficiency, scalability, and quality.

Automation refers to the technical support or complete execution of processes through technologies such as conveyor systems, automatic sorters, or automated guided vehicles and packaging equipment. 

Robotics goes a step further – here, autonomous or semi-autonomous warehouse robots and cobots take over tasks such as loading and unloading, rack handling (rack-to-person systems), palletizing and depalletizing, or pick-and-place operations.

Artificial intelligence complements both automation and robotics by managing intelligent control systems in the background. It analyzes movement data, optimizes warehouse layouts, dynamically prioritizes order picking, and helps robots detect their environment and navigate efficiently. The interaction of automation, robotics, and AI is key to developing resilient, future-proof warehouse automation solutions.

Our automation strategy is modular and adaptable across industries – from Healthcare and Fashion to Tech. Below are selected applications we have already in place:

Goods Inbound & Storage

At our U.S. site in Louisville, we use the Stretch robot by Boston Dynamics, which can unload up to 500 individual loose loaded cartons per hour from containers. Stretch handles mixed-size cartons up to 23 kg and takes over a physically strenuous task, improving both speed and employee well-being. Read more about our partnership with Boston Dynamics in our Partner Success Story.

We also use AI-supported palletizing robots for depalletizing operations. These intelligent robotic arms can transfer up to 750 cartons per hour from incoming pallets to conveyor belts for further storage.

Across many locations, we deploy automated guided vehicles (AGVs) to handle internal transport, as well as the putaway and relocation of goods. In addition, we utilize industrial unloading robots, telescoping conveyors, parcel pickers, and automated master data logging tools to optimize inbound flows. These solutions minimize walking distances, reduce handling errors, and help offset the growing shortage of skilled forklift operators. Furthermore, we use industrial unloading robots, telescoping conveyors, parcel pickers, and automated master data logging tools to optimize inbound flows. 

Systems like shuttle systems and AutoStore also play a crucial role in optimizing warehouse space and increasing item availability. They support high-density storage and enable faster access to inventory. Items are delivered directly to picking stations, reducing walking distances for staff and streamlining the entire picking process. In collaboration with our partner KNAPP, we’ve implemented Europe’s largest 2D shuttle system for beauty and cosmetics at our site in Hamm to support our client Douglas’ omnichannel fulfillment strategy. Learn more about Europe’s largest 2D shuttle system in our Partner Success Story with KNAPP.

Order Picking

At sites like Illescas (Spain), Poznań (Poland), and Harsewinkel (Germany), we use rack-to-person systems where autonomous warehouse robots bring shelving units directly to picking stations. This not only saves time but also significantly reduces physical strain on employees. AI systems prioritize items by order frequency and shipping urgency.

As a smart extension to AutoStore, we’ve also implemented the justPick robot from Nomagic. This solution enables fully automated picking and returns handling without the need to alter existing infrastructure.

The next step in order picking is our self-developed picking robot Leleka at our site in Hanover, which is designed to insert single order items into our bag sorter system.

Packaging & Shipping

Our automated packaging systems adjust the carton size to fit the specific item, seal shipments efficiently, and optimize or even eliminate void fill – contributing to our sustainability goals.

In addition, we use automatic label applicators that apply shipping labels with precision and speed, improving throughput and reducing labeling errors – especially important for high-volume e-commerce fulfillment operations and short delivery windows.

One example: At our Dorsten site, we’ve implemented a state-of-the-art packaging system to boost flexibility and performance in online order handling. Learn more about our automated packaging solutions.

Outbound logistics benefit from advanced telescoping conveyors, automated loading systems, and smart solutions like Q-Loaders. These technologies ensure speed, precision, and reduced manual effort during the final phase of fulfillment.

For our clients, the targeted use of automation and robotics means one thing above all – measurable value.

Automated processes allow us to handle higher volumes faster and with a very low error rate – especially important during e-commerce peaks or for time-critical healthcare shipments. Our modular systems enable us to flexibly adapt to increasing order volumes or changing client requirements without long lead times. And thanks to a high level of automation, we can maintain consistent quality and service availability – even during labor shortages or seasonal fluctuations.

Crucially, by automating physically demanding tasks, we not only increase productivity but also improve workplace conditions – an increasingly important factor in a competitive labor market.

Our goal for the coming years is to implement solutions that not only improve operational performance and flexibility but also increase storage density and throughput. With this approach, we create more scalable, space-efficient environments that are easier to adapt to changing client needs.

Automation and robotics are not just part of Arvato’s infrastructure – they are a key driver of our growth strategy. Combined with deep logistics expertise and international experience, we deliver warehouse automation solutions that are scalable, secure, and future-ready.

Whether in e-commerce fulfillment, healthcare, or high-tech logistics: Arvato is the right partner for companies that want to combine advanced technology with operational excellence.