Partner Success Story | Hai Robotics
How We Enable Scalable Omnichannel Fulfillment With Hai Robotics
We are combining robotics, software integration, smart warehouse processes, and operational execution into one scalable warehouse ecosystem.
Omnichannel retail logistics is becoming increasingly complex. Rising customer expectations, growing SKU assortments, and volatile promotional peaks are putting traditional warehouse operations under pressure. Especially in premium retail environments, fulfillment operations must combine speed, accuracy, scalability, and operational stability while maintaining high service levels across both B2B and B2C channels.
Together with Hai Robotics, we created a solution designed for real-world omnichannel fulfillment environments. Our joint project — the implementation of a highly automated solution for a leading European premium beauty retailer at one of our sites in Italy — not only demonstrates our operational capabilities. The approach behind it is even more important: We are combining robotics, software integration, smart warehouse processes, and operational execution into one scalable warehouse ecosystem.
Scalable Omnichannel Fulfillment in Action
A Partnership Focused On Scalable Fulfillment Efficiency
Modern fulfillment operations require more than standalone automation technologies. The real challenge lies in combining storage density, throughput performance, operational flexibility, and seamless systems integration within increasingly limited warehouse space.
This is where our new solution creates value. Together, we designed a scalable automation setup tailored to the requirements of premium beauty logistics, where high SKU complexity, strong service-level expectations, and volatile peak volumes demand both efficiency and adaptability.
While Arvato managed the overall logistics setup, including WMS and WCS integration as well as the coordination between automation, warehouse processes, and IT systems, Hai Robotics contributed its HaiPick System 3 (HPS 3), including automated case-handling robots, flow rack technology, and the underlying automation framework.
High-Density Storage Meets Operational Flexibility
A key advantage of the solution is not only its efficient use of warehouse space, but the combination of high storage density, direct case access, and operational flexibility within a compact footprint. By utilizing vertical storage heights of up to 12 meters, the system provides more than 88,400 storage locations within only 4,000 sqm of warehouse space.
Unlike highly condensed cube-storage systems, the setup enables direct access to individual cases while also supporting sprinkler-compatible rack structures, an important requirement for handling specific product categories and dangerous goods. In addition, the solution allows automated replenishment of flow rack picking zones for fast-moving SKUs, helping maintain stable throughput and efficient order processing during both daily operations and promotional peaks.
For the client, this creates a fulfillment infrastructure capable of supporting continued e-commerce growth and increasing SKU complexity while maintaining the speed and reliability expected in premium beauty retail. At the same time, reduced walking distances, less manual handling, and more consistent order processing contribute to greater operational stability and higher throughput during daily operations as well as promotional peaks.
Beyond the technical performance of the system, the solution provides tangible operational benefits for the client. Increased storage capacity within the existing footprint creates room for future assortment growth without requiring additional warehouse space. Automated replenishment and optimized goods-to-person processes help improve fulfillment efficiency, while the combination of scalability and process stability enables the operation to respond more effectively to seasonal peaks, promotional campaigns, and changing customer demand patterns.
Why Traditional Warehouse Setups Reach Their Limits
Modern omnichannel environments face a unique combination of operational challenges:
- Rapidly increasing order volumes
- High SKU complexity
- Simultaneous B2B and B2C fulfillment flows
- Strong seasonal and promotional peaks
- Increasing pressure on operational stability and delivery speed
Traditional warehouse layouts based on manual picking processes often struggle to adapt efficiently to these dynamics. Expanding capacity frequently requires additional warehouse space, increased labor requirements, or major infrastructure changes. At the same time, many conventional automation systems remain too rigid to respond quickly to evolving needs.
The objective of the joint Arvato and Hai Robotics solution was therefore not only to automate processes, but to create a logistics environment that combines scalability, flexibility, and long-term operational efficiency within one integrated setup.
The focus was on maximizing storage capacity within a compact footprint, reducing manual handling effort, and enabling stable throughput performance while maintaining the adaptability required in fast-changing retail environments.
Here we manage business requirements ranging from B2C to B2B within an omnichannel logic. Having automation that can respond to these needs, including speed, adaptability, and peak management, is a key success factor – for us and our clients.
Philipp Rücker Head of Logistics Engineering & Transport Management at Arvato
Building a Flexible Robotics-Driven Fulfillment Environment
At the core of the solution is HaiPick System 3 (HPS 3), a high-density automation system designed for omnichannel operations.
Within the automated environment, automated robots replenish storage locations directly from the rear, enabling highly flexible workstation and flow rack configurations. This setup allows warehouse processes to be adapted precisely to operational requirements while optimizing space utilization and goods flow efficiency. The modular architecture supports seamless alignment between robotics systems, warehouse processes, and IT infrastructure. This enabled the design of a highly compact and scalable setup capable of handling more than 3,000 totes per hour throughput capacity.
Designed for Peak-Volume Performance
The automation infrastructure significantly reduces operator walking distances and manual handling activities while also lowering physical strain on employees. At the same time, vertical storage utilization of up to 12 meters maximizes space efficiency within the available warehouse footprint. The system supports highly complex beauty assortments with more than 88,400 storage locations across omnichannel fulfillment flows. Integrated coordination between WMS and WCS systems further improves picking accuracy and process consistency, supporting the high service-level expectations typical of premium beauty retail.
Most importantly, the modular setup creates a scalable operational foundation that can evolve alongside future growth in order volumes and SKU complexity without requiring fundamental redesigns of the warehouse environment. This contributes to more stable fulfillment performance, particularly during promotional and peak periods where speed and reliability become critical.
When working with Arvato, we especially recognized the willingness to rethink fulfillment processes and turn innovation into practical operations. From the beginning, there was a shared understanding that automation should not only increase efficiency, but also create smarter, more adaptable fulfillment environments that can evolve with future business requirements. This mindset fits very well with how we at Hai Robotics approach innovation and long-term collaboration.
Alexander Peschel Solution Director at Hai Robotics EMEA
Enabling Future-Ready Operations
For our client, the project creates a fulfillment environment that is prepared for continued growth in e-commerce volumes, expanding product assortments, and increasingly dynamic customer expectations. Rather than simply adding automation, the solution establishes a scalable operational foundation that supports long-term efficiency, service quality, and business agility.
The collaboration between Arvato and Hai Robotics demonstrates how the focus in warehouse automation is shifting from simply implementing robotics technologies to building operations that combine operational efficiency, flexibility, and scalability within one integrated solution architecture.
As omnichannel retail continues to evolve, automation systems must increasingly support dynamic fulfillment requirements, fast operational adjustments, and sustainable long-term growth. By combining robotics innovation with operational execution and systems integration expertise, we are creating solutions designed to meet exactly these requirements.
