Expanding Our AutoStore™ System to Accelerate Our Clients’ Growth

Rising expectations among B2C and B2B customers across different markets are increasingly putting tailored supply chain solutions at the center. This trend is reflected in a recent project in the UK, where we welcomed a new international client, a leading brand in technical athletic apparel. The client was looking for a flexible and reliable solution to keep up with rising end customer expectations and the fast-paced UK market. 

To ensure a seamless and efficient start for their operations, we expanded our existing AutoStore system — implemented together with our technology partner AutoStore and the integrator Kardex — at our Hams Hall site in Birmingham. As a result, we expanded our capacity in a targeted way and ensured a stable operational setup. The project was completed in just over three months, enabling a smooth onboarding process and reliable fulfillment from day one.

This rapid expansion builds on the successful initial implementation of the system in 2023, which was completed in just seven months and represents the fastest implementation in our company’s history.

As our clients continue to scale, so does our responsibility to deliver faster, smarter, and more flexible fulfillment. "Since launching our AutoStore solution in August 2023, we’ve significantly boosted productivity, scalability, and service quality," says Steven Pitt, Head of Operations at Hams Hall. "The compact design and automation have maximized warehouse space while reducing costs." 

The enhancement increases the number of storage bins from 65,000 — previously managed by 130 R5 robots — to about 87,600 bins, now overseen by 165 R5 robots, boosting the AutoStore capacity by an impressive 30%. Picking capacity has grown from 17,000 to over 26,000 orders per day during peak season, compared to a manual picking solution. The storage capabilities were expanded to nearly 1.2 million units. With the additional outbound ports, the AutoStore can now handle over 90,000 units per day. "These improvements, along with better order fulfillment, have increased our capacity and already attracted a new client to the UK," says Steven Pitt.

"AutoStore technology is a perfect match for our dynamic growth in the UK market," says Tim Godejohann, Project Lead Logistics Engineering. "Integrating it through our own Warehouse Control System enables short implementation timelines and further enhances the flexibility of the solution. That speed and adaptability allowed us to meet every expectation from our client seamlessly."

To ensure a seamless and efficient start for their operations, we expanded our existing AutoStore system — implemented together with our technology partner AutoStore and the integrator Kardex — at our Hams Hall site in Birmingham. This strengthened our capacity and reinforced our commitment to operational excellence. The expansion project was completed in just over three months, supporting a smooth onboarding process and enabling high-performance fulfillment from day one.

The quick expansion lived up to our high expectations, as the initial implementation of the system in 2023 had already set the bar high: We completed it in just 7 months, the fastest implementation in our company’s history.

"At Arvato, we continuously evaluate and implement innovative technologies to ensure the most effective solutions for our clients," adds Walid Mouelhi, Vice President Solutions Engineering. "With over ten successful implementations, in partnership with AutoStore, we have built extensive expertise in deploying scalable, high-performance automation.

The Hams Hall expansion is a testament to our strategic approach in leveraging this experience to enhance multi-client capabilities, dynamically respond to peak demands, and rapidly scale capacity.

By successfully completing this expansion, we’re not just growing our own capabilities, we’re investing in our clients’ long-term success, today and for the future."