More automation – that’s what every warehouse operator wants. From intelligently linked subsystems to fully automated facilities: How Linde Material Handling and Dematic implement comprehensive performance improvements in the warehouse through shuttle systems, AGVs/AMRs, AutoStore™, WMS/WCS, and AI driven orchestration.
2025-08-13
Selectively automated individual solutions often suffice for many companies and small businesses. But when throughput, complexity, or transparency requirements increase, you need systems that go beyond isolated optimizations – systems that intelligently link individual processes or orchestrate the warehouse as a whole.
At KION, we distinguish four levels of automation:
Levels 1 and 2 were covered in this article. Levels 3 and 4 focus on networking conveyor technology, robotics, software, and control systems – with significant impact on productivity and process reliability in the warehouse.
The system is tailored to the specific needs of Servicio Móvil.
Several automated components such as shuttle systems, conveyor technology, AutoStore™, palletizing robots and higher-level software work together. Orchestration by a Warehouse Control System (WCS) or Warehouse Management System (WMS) is especially crucial.
Advantage: When multiple processes are intelligently linked, a consistently efficient flow of materials emerges. Conveyor technology, shuttle systems and higher-level software provide speed, transparency and clear organization in the warehouse – ideal for companies with high throughput and complex operations.
At the Spanish logistics service provider Servicio Móvil, the introduction of an AutoStore™ system from Dematic has revitalized everyday warehouse operations and significantly lightened the workload for on-site employees. Compact containers, intelligent robots and a tailored software solution ensure orders are processed quickly, accurately, and efficiently – a true advantage, especially in the demanding healthcare sector. The system boosts picking productivity by up to 80 percent while greatly enhancing accuracy. Thanks to its high scalability, Servicio Móvil is well positioned for future growth. For the team, this means less stress, faster operations and increased reliability in daily tasks.
The pallet shuttle warehouse of Fosfa logistics.
This highest level encompasses full automation of all processes from goods receipt to shipping. Fully automated systems combine warehouse technology, transport, software and robotics – the complete spectrum. Solutions range from multi-shuttle systems, high-bay warehouses and pallet shuttles to AGVs and AMRs, as well as plant control using artificial intelligence and fully integrated supply chain execution platforms.
The benefits: maximum process speed, minimal error rates and a high level of automation while maintaining quality – a sustainable solution for scalable growth.
In the Czech Republic, our subsidiary Linde MH implemented a fully automated warehouse with 4,500 pallet locations for the chemical company Fosfa. The facility integrates an automated shuttle storage system with autonomous Linde vehicles that pick up pallets at designated interfaces and transport them to transfer points. All operations are managed through a WMS that simultaneously communicates with ERP systems (Enterprise Resource Planning), making it a company-wide software solution digitally linking core business processes including production, procurement, warehousing and order processing. The system operates nearly autonomously, resulting in a significant increase in picking speed and fulfilling customer orders within one day.
The spare parts warehouse in Kahl requires a high degree of automation due to its high throughput.
We implemented this flagship project to supply spare parts for our own products: The KION Regional Distribution Center Central Europe in Kahl am Main features a 30-meter-high, fully automated high-bay warehouse with six aisles, plus a powerful multi-shuttle system with 110,000 storage locations. In addition, it includes an intelligent flow of materials with continuous conveyor technology, along with autonomous mobile robots (AMRs) and industrial trucks. The combined expertise of our Dematic and Linde Material Handling brands showcases the full breadth of our capabilities as the KION Group – also representing the current state of automation and digital technology, safety and energy solutions, and seamlessly integrated material flow systems.
The concept at the Kahl spare parts center includes permanently installed, fully automated systems as well as autonomous mobile robots (AMRs).
The various levels of automation demonstrate how diversely automation solutions can be designed – without a fixed sequence, but always focused on specific needs.
Whether manual, semi-automated or fully integrated: KION Group brands provide technologies, consulting and implementation expertise for each of the four levels of warehouse automation. This enables companies to start step by step, expand strategically, and scale up as needed to a fully automated comprehensive solution.
