What is AutoStore? A Complete Guide to AutoStore ASRS

Does AutoStore (the company) sell AutoStore (the system)?

AutoStore is a proprietary system manufactured by its namesake company, AutoStore. AutoStore (the company) manufactures the systems and develops the software that controls the robots' movement. But it doesn’t install or maintain AutoStore systems or provide the warehouse execution software (WES) to orchestrate AutoStore movement with other automated solutions.

What is an AutoStore integrator?

Instead of selling systems directly to customers, AutoStore partners with integrators. These logistics companies manage every step of getting the AutoStore ASRS into the customer's warehouse—from creating quotes to offering post-install service plans. Integrators collaborate closely with customers to:

• Design the system that works best for their warehouse.
• Develop customized software to integrate AutoStore ASRS systems with other warehouse automation solutions and warehouse management systems (WMS).
• Install AutoStore system hardware.
• Integrate and test software. 
• Maintain and service AutoStore systems (customer-dependent).

How does AutoStore work?

Products move from input ports, where they are placed in bins, to storage within the grid. When an order is received, robots bring the bin containing the product to an output port for picking. In more detail: 

1. Workers place products in AutoStore bins at the input ports, also known as put-away stations. 
2. The bins move into the AutoStore grid, where products can be stored indefinitely. 
3. Depending on demand, products will move within different layers of the AutoStore ASRS system. High-demand products remain near the top of the grid for easy access, while low-demand products move deeper into the grid. 
4. The WES batches orders to optimize retrieval. 
5. Robots pull bins containing products and carry them to ports. 
6. A worker or piece-picking robot removes products from the bin and either packs the order at the port or sends it to a packing station.

What are the different parts of an AutoStore ASRS?

Each AutoStore installation is unique. Grid shape and size and number of bins, robots, and ports vary by warehouse throughput, SKU variety, and facility requirements. However, all AutoStore systems have four basic components: 

• AutoStore grid: Durable, lightweight aluminum structures hold the bins in place and provide a scaffold for the robots. 
• AutoStore bins: Shelving within the grid holds bins. Bins must be the same height within an individual AutoStore system but can be divided to contain different SKUs. 
• AutoStore robots: Automated units equipped with lifting straps and a gripper plate retrieve bins from the grid and then bring them to the grid columns connected to the ports for picking or restocking. 
• AutoStore ports: Inbound products are placed in bins at ports, and outbound products are picked to either be packaged at the picking station or sent to another area of the warehouse for packing.

Absolutely. AutoStore ASRS pairs well with other automated warehouse technology—when equipped with the right WES. You can use conveyors, piece-picking robots, carousels, autonomous mobile robots (AMR), and more alongside an AutoStore ASRS to complete your intralogistics system. 

Here’s a hypothetical example of multiple automated components working together within a single facility: 

• High-bay ASRS stores larger items and pallet loads
• AutoStore ASRS processes small and medium-sized items 
• Conveyors link automated solutions 
• AMRs move goods to picking stations
• Piece-picking robots supplement human operators

A high-performing, intelligent WES is critical to combining automation solutions. The WES orchestrates the disparate systems to optimize operations. 

Can AutoStore be expanded later? 

Yes; AutoStore ASRS are designed to grow with your business. You can expand AutoStore systems over time by increasing the number of robots, bins, or ports. Which component you increase depends on your needs.  

What is the difference between an AutoStore and a shuttle system?

Both AutoStore ASRS and shuttle systems rely on automation to move products within a warehouse or distribution center. However, AutoStore keeps products within its grid, while shuttle systems move products between different parts of the warehouse. AutoStore ASRS has higher storage density than a shuttle system, meaning it holds more product while taking up less floor space. In addition to optimizing floor space, AutoStore ASRS can be easier to implement and expand than a shuttle system because of its modular design.

Are AutoStore grids customizable?

Yes. AutoStore grids are modular and can be tailored to each warehouse. For example, AutoStore grids can span multiple floors or encompass existing architectural features (such as pillars) in brownfield sites. You can also expand the structure as SKU counts or product volume increase.

How many boxes can an AutoStore grid store?

How many boxes do you need? AutoStore grids can incorporate anywhere from 5,000 to 300,000 storage boxes. The grid structure’s maximum height is 6 meters, and it requires 1.8 meters of ceiling clearance for the robots to operate. However, AutoStore grids can scale almost indefinitely in length and width.

How does a fire suppression system work with AutoStore grids?

Fire suppression systems, such as sprinklers, must be mounted outside of the AutoStore grid. If the product intended for storage and retrieval in your AutoStore requires fire suppression systems to be installed very close to where it is stored, consider other automated solutions.

What types of robots does AutoStore use?

AutoStore’s current robot lineup is the Red Line: the R5, R5+, R5 Pro and R5+ Pro. All Red Line robots have a bin-lift mechanism mounted on the robot’s main body. AutoStore introduced the Black Line (B1 robot) in 2019 for very high-throughput systems, and it was deployed on some projects. With the introduction of the R5 Pro robots, however, the Black Line offering was discontinued because both lines offered similar product features. Sites that already run B1 robots can still expand their systems with R5+ robots.

Within the Red Line, the main difference is between the standard models (R5 and R5+) and the Pro models (R5 Pro and R5+ Pro). Pro robots are built for large, multi-shift operations: they achieve higher throughput per robot, so the same workload needs fewer robots and fewer charging stations. The taller “+” models (R5+ and R5+ Pro) are the only AutoStore robots that can carry all three bin sizes, including the 425 mm bin.

How many AutoStore robots do I need?

The number of AutoStore robots you need depends on your throughput requirements. There is not a set number of robots deployed with each AutoStore system. Because the system is modular, you can easily add or remove robots to accommodate demand fluctuations.

How much energy do AutoStore robots use?

Lower energy use reduces operational costs—an important consideration when evaluating new warehouse technology. AutoStore robots use only 0.1 kW of energy per hour. This means six AutoStore robots use the same amount of energy as a household toaster.

Can I use my own bins in an AutoStore?

When transitioning from traditional aisle-and-shelving storage to AutoStore, it can be tempting to use existing hardware. However, you must use AutoStore bins in an AutoStore system. The AutoStore bins feature custom gripper plates and are manufactured to meet the tight tolerances required to operate within the high-density AutoStore grid.

What products can AutoStore handle?

AutoStore ASRS handles products that fit within the storage bin capacity and 30 kg weight limit. This includes small and medium-sized items.  
Product size restrictions don’t limit the industries AutoStore supports. For example, in a distribution center for an e-commerce fashion company, an AutoStore system can process most types of clothing and accessories. In an automotive parts warehouse dealing with a variety of SKU types, the AutoStore system could handle small components, such as spark plugs, while other ASRS solutions store larger or unwieldy parts, such as windshields.

What sizes are the AutoStore bins? Do the AutoStore bins have a weight or volume limit?

AutoStore bins come in three heights to accommodate different SKU types. They can also be divided to carry multiple SKUs within a bin. Each AutoStore bin size has a maximum load capacity of 30 kg. The heights include: 

• 220 mm storage bin: carries up to 49.08 liters
• 330 mm storage bin: carries up to 75.81 liters
• 425 mm storage bin: carries up to 98.17 liters

The tallest AutoStore bin requires the AutoStore R5+ Pro robot to operate. The shorter AutoStore bin sizes are compatible with all robot types.

Does stacking bins slow AutoStore down?

Reaching products stored farther down in the AutoStore system takes longer than reaching those stored at the very top. However, over time the system will naturally place more commonly picked SKUs on top, while less commonly picked items end up near the bottom. Intelligent software can further improve this process.

How fast is AutoStore? How many picks per hour can AutoStore systems handle?

AutoStore robots zip along at up to 3.1 meters/second—similar to a brisk jog. With strategic WES helping map storage and pickup locations, an AutoStore ASRS can process 20,000 or more picks per hour, making it the fastest ASRS per square foot available worldwide.

After the operator logs in, the first bin arrives within minutes. Then bins are presented to operators continuously. In high-throughput systems, AutoStore can present 30 to 40 bins per hour, with a few seconds of exchange time. 

Picking speed depends on order profile. For large orders picked from multiple bins, operators can generally perform at least 250 picks per hour. For smaller orders picked from a single bin, picking speed increases to 350 picks per hour. Installing ports optimized for picking and batching orders can further increase picking speed up to 650 picks per hour.

What are the different types of AutoStore ports?

AutoStore currently offers ten port and workstation types, and integrators combine them to fit each warehouse’s workflow. Options include:

• CarouselPort: Bins rotate on a built-in carousel beneath the picking opening, so the next bin is ready while the operator picks from the current one. CarouselPort also supports inserting and removing bins from the grid.
• ConveyorPort: Bins enter the workstation on a conveyor, one after the other, and conveyor speed adapts to each operator. Its simple design gives access to all bins in the grid.
• FusionPort: AutoStore’s ergonomic, high-speed port handles up to 550 bins per hour through two independent bin openings. Openings tilted at 15 degrees, safety hatches and built-in pick-to-light reduce the reaching and twisting that cause fatigue on long shifts. 
• FusionPort Staging: Combines picking and staging at the same station, so operators can return finished orders to the grid and free up floor space. 
• VersaPort: A low-cost, modular workstation with a safety hatch. Ports run alone or link in groups of up to three for inbound, picking, consolidation, kitting or pick-and-stage workflows, at up to 180 bins per hour (240 on a mezzanine). 
• SwingPort: Rotating arms bring bins from the storage bin lift to a workstation outside the storage area that stays connected to the grid. SwingPorts work well with multi-level AutoStore ASRS configurations. 
• RelayPort: Robots present multiple bins simultaneously for better order sequencing and fast item exchange between robot and operator. 
• PickUpPort: Consumers collect orders directly from publicly accessible ports, enabling in-store pickup. 
• CarouselAI: Adds an AI-driven robotic arm to the CarouselPort for automated piece picking. AutoStore rates it at up to 650 units per hour and around 90% of typical e-commerce SKUs. 
• VersaAI: A lights-out robotic workstation that works inside the grid, pre-picking and buffering orders and consolidating partially filled bins during off-peak hours.

Are all AutoStore ports the same?

As with the other AutoStore system components, AutoStore ports can be customized to meet each warehouse's needs. The ports can bring items to ergonomic workstations staffed by workers or piece-picking robots. Ports typically bring products to workers via a built-in carousel, but can use conveyors instead or include different sequencing and staging options.

What is the ROI for an AutoStore system?

The first question stakeholders ask is when they will start seeing the benefits from purchasing and setting up AutoStore cube-based storage in their warehouse. Typically, companies achieve return on investment (ROI) within two to three years of implementing an AutoStore system. ROI comes from: 

• Labor savings 
• Higher throughput
• Increased storage density 

Is AutoStore ASRS worth it?

Compiling the costs for purchasing, building, and maintaining an AutoStore ASRS can feel overwhelming, but the value the system delivers offsets the costs. If AutoStore is the right fit for your warehouse, it can deliver: 

• Labor savings: direct full-time employee reduction and reduced reliance on temporary labor, shift count costs (e.g., supervision, utilities), and recruiting and onboarding costs.
• Expansion within existing facilities: avoid the extensive expense of a new build or expanding existing buildings, consolidate operations if possible, increase active pick facings for simultaneous picking, free up real estate if consolidating operations. 
• Reduced capital equipment costs: including powered equipment (e.g., forklifts), racking, and pick modules.   
• Operational and strategic benefits: improve shipping rates, avoid carrier upcharges, expand SKU range, create a safer working environment by reducing manual labor requirements, increase performance consistency.

Since AutoStore ASRS can last over 20 years, factor the total cost of ownership for a holistic, accurate view of system costs. Consider upfront capital expenditure and implementation costs, plus inflation-adjusted ongoing costs such as maintenance, system upgrades, and staffing.

What are the upfront costs of owning an AutoStore? 

AutoStore system hardware and software can cost tens of millions of dollars. The exact figure depends on grid size, number of robots, number of picking ports, and add-on components. Each AutoStore is unique, and the price varies accordingly. 

In addition to capital expenditure on the system, AutoStore upfront costs include: 

• Site preparation, such as leveling floors before system installation 
• Electrical and infrastructure upgrades to accommodate the system
• Systems integration and IT project costs
• Productivity losses during the transition period 
• Staff training 

What ongoing costs does an AutoStore ASRS have?

Once your AutoStore is in place, expenses include software fees, maintenance and service costs, and spare parts holding expenses. Consider: 

• WMS, warehouse control system (WCS), and WES licensing 
• Integration middleware for enterprise resource planning (ERP), order management system (OMS), and transportation management system (TMS) software  
• Preventative maintenance such as inspections, calibrating equipment, and replacing worn parts 
• Emergency maintenance services to fix parts during peak productivity hours
• Carrying on-site spare parts inventory for critical components 
• Dedicated maintenance teams 
• Service contracts with AutoStore integrators

What kind of maintenance does an AutoStore system need?

Maintenance is an important consideration for warehousing, where facilities often operate long hours with few breaks. AutoStore ASRS robots will require periodic maintenance and servicing. The AutoStore grid has a spot for robots with problems to pull off and move to a service area. When a robot is down, another can take its place to sustain throughput. 

How do I train staff to maintain an AutoStore? 

AutoStore integrators can help train staff to operate, troubleshoot, and maintain the system. Many AutoStore integrators also offer service packages that include full-time, onsite staff or dedicated teams available to address any issues that arise.

The benefit of onsite AutoStore maintenance and service teams from integrators is a direct line to the system designers and immediate support. As integrator employees, they also don't rack up the same costs as traditional employees (e.g., benefits, insurance, administrative costs, supervisory hours, etc.).

AutoStore systems offer major benefits by increasing throughput, easing workforce woes, improving flexibility, and meeting growing demands. In most cases, there is a strong argument for using AutoStore in your warehouse. In some cases, other types of automation may better meet the need. 

What factors should I consider before choosing AutoStore for my warehouse? 

Use the following factors to help determine if AutoStore is right: 

• SKU volume: Do you have a lot of different types of SKUs coming through your warehouse? Or do you typically deal with limited SKUs? AutoStore can handle any SKU volume, but the system is especially well-suited for high-volume warehouses because it can store multiple items in a single bin. 
• SKU type: Are you dealing with large or small products? Or a mix? If dealing with large variances in size and shape, consider vertical lift modules or high-bay ASRS over AutoStore since the system is limited by bin height.
• SKU distribution: AutoStore holds the most benefit for warehouses that need to store many products but only see a small percentage of those products leave. For example, 20% of SKU volume may drive 80% of the orders. Since the most important products naturally move closer to the top of the shelves, this situation is ideal for AutoStore. If your SKUs are equally popular, another ASRS solution will better optimize your operations. 

Can AutoStore be used in e-commerce?

Absolutely, AutoStore can be used in e-commerce and retail. AutoStore ASRS drastically increases throughput to meet consumer demand for rapid delivery and accurate orders. By automating manual tasks, AutoStore systems can increase pick performance by 50% or more, saving hours in order fulfillment. AutoStore ASRS can also be combined with automated solutions, such as piece-picking robots and packing automation, to further speed up fulfillment.

Is AutoStore ASRS right for fashion and retail companies?

Yes, AutoStore ASRS can provide the scalability and speed fashion and retail require. Consumer demand changes quickly, and warehouses, distribution centers, and back rooms need the flexibility to adjust. The AutoStore system offers:

• Incremental investments: scale as your business grows 
• Flexible fulfillment: custom options tailored to your SKU type and volume
• Omnichannel fulfillment (e-commerce and store replenishment options) 
• High-density storage to speed fulfillment 

Case study—AutoStore streamlines and simplifies order fulfillment for an industrial equipment retailer

United States retailer Northern Tool’s manual, three-level pick module didn’t provide enough support to meet customer demand. The company integrated an AutoStore ASRS with their custom packaging technology to pick orders directly into right-sized boxes. The custom solution freed almost 50,000 square feet of warehouse space while optimizing direct-to-customer and store fulfillment. 

How does AutoStore ASRS benefit the food and beverage industry? 

To meet regulatory requirements, food and beverage companies often need to store products for specific time periods at specific temperatures. AutoStore ASRS can operate in frozen and refrigerated environments and provide visibility and real-time inventory insights, so food and beverage companies know exactly what products are available.

Can AutoStore be used in grocery distribution?

Automating storage and retrieval with AutoStore ASRS meets many challenges for grocery distribution companies, including: 

• Expanding e-commerce capability and store replenishment—all within the same system 
• Providing the option to create micro-fulfillment centers to accelerate deployment time
• Reducing product waste by ensuring timely handling
• Managing chilled, frozen, and ambient temperature goods in one system
• Improving inventory visibility and accuracy

Case study—Tri-temperature storage with AutoStore ASRS

French grocer La Réserve des Saveurs implemented a first-of-its-kind AutoStore ASRS to store and retrieve frozen, refrigerated, and dry products within the same building. Typically, these item categories are stored in separate facilities. The new system centralized all orders, reducing the grocers’ carbon footprint and improving efficiency.

How can AutoStore benefit the aerospace and automotive industries?

Assembling cars, trucks, and planes requires many small and medium-sized components. AutoStore systems can’t store and retrieve windshields or landing gear, but they can easily and quickly gather the other items needed to create them.   

AutoStore ASRS can also support aftermarket aerospace applications. For example, Satair Singapore used an AutoStore to manage approximately 80% of its small and medium-sized spare aircraft parts. The aerospace logistics company can get parts to customers in Southeast Asia quickly and accurately.

How do I choose an AutoStore integrator?

Who you choose to work with can determine the project's success. Look for an experienced AutoStore integrator with a high customer return rate and a reputation for excellent customer experience. Consider the integrator’s service plan options and any technical differentiators. Prioritize integrators with a collaborative mindset, a deep portfolio, and proven dedication to developing AutoStore products within their company. 

What are the AutoStore implementation steps?

Generally, AutoStore implementations follow similar steps. Once customers approve the integrator’s quote, the integrator finalizes the design and confirms the order to AutoStore (the company) to deliver the hardware (mainly robots, charging stations, controls) according to project plan. While AutoStore assembles the robots, the integrator orders bins, grid structure, other construction elements and customizes the software, and the customer prepares their warehouse and WMS. 

The full responsibility for the AutoStore commissioning is with the integrator. The experts come on-site to install the hardware and software. Integrators and customers ramp up the AutoStore system and the integrator hands over the system to the customer when previously agreed acceptance criteria are met. The system is ready to go live.

What is the AutoStore software development process?

AutoStore integrators customize software for each implementation. The process includes: 

• Meeting with customer operations and software teams to develop functional specifications
• Software development and testing
• Installation 
• Onsite and user acceptance testing 

How long does it take to install AutoStore?

For an average-sized system with average complexity, AutoStore ASRS installation takes 10 to 14 months. Although 6 months is often quoted as the standard AutoStore ASRS installation time, installations rarely happen that quickly without drastically increasing expenses and simplifying the system. Factors that impact AutoStore installation timelines include:

• System size
• Number of add-on components 
• Customer response time
• Testing requirements
• Site access
• WMS readiness
• Permitting