Dark Warehouses – Autonomous Logistics
24 hours a day, 7 days a week, efficient and future-proof.
Skill shortages, rising costs, volatile markets, and increasing customer demands are creating enormous challenges in the industry. At the same time, customer expectations regarding speed, transparency, and availability continue to grow.
Dark warehouses are fully autonomous and control and execute logistic processes without the need for constant monitoring. Material flows organize themselves; vehicles navigate autonomously; storage and systems operating around the clock, while IT systems optimize inventory levels and routes in real time.
The result is a logistic system that is not only automated but also intelligent and self-steering. However, what obstacles need to be overcome to get there?
Our approach
Holistically designed, fully integrated, and future-focused implementation.
Autonomous logistics do not emerge from individual technologies but from the integration of processes, automation, IT, and building infrastructure.
We develop a comprehensive vision for our clients and support implementation from strategy through operations.
Our services include:
- Analysis of existing logistics and IT systems
- Evaluation of automation and digitalization levels
- Development of a target vision of “autonomous logistics”
- Business case development and ROI assessment
- Roadmap for step-by-step transformation
- Value stream analysis and process optimization
- Development of processes suitable autonomous operations
- Layout and scenario planning
- Material flow simulation
- Definition of the desired level of automation
- Automated guided vehicles (AGVs) and autonomous mobile robots (AMRs)
- High-bay warehouse and shuttle systems
- Robotics for picking and palletizing
- Conveyor and sorting systems
- Automated loading processes
We act in a vendor-neutral, future-oriented manner with scalable solutions.
- WMS strategy and selection
- Integration of ERP, MES, and material flow control systems
- Data and interface architecture
- Cybersecurity measure
- Digital twin logistics solutions
Autonomous logistics places new demands on the physical environment. We integrate:
- Structural and warehouse building design
- Floor load and structural requirements
- Fire protection and safety systems
- Energy and charging infrastructure
- 5G and network planning
- Lighting and emergency concepts
- Integrated technology and buildings from the outset
- CE compliance and safety requirements
- Human-machine interaction concepts
- Emergency and intervention strategies
- Maintenance and service planning
- Organization of future operations
Our Process
Phase 1: Target Analysis and Vision
- Ensuring transparency and strategic alignment
- As-is analysis and maturity assessment
- Identification of automation potential
- Business case development and analysis
- Developing of a master plan
The result is a decision-ready strategy and a robust business case
Phase 2: Concept and Planning
Wir entwickeln die umsetzungsreife Lösung:
- Developing a ready-to-implement solution
- Detailed material flow and layout design
- Technology definition and system selection
- IT architecture design
- Specifications and tendering
- Schedule and investment planning
- Development of a digital twin
The result is an approved plan and partners engaged for implementation.
Phase 3: Implementation and Ramp-up
- Ensuring successful execution
- Engineering and construction coordination
- System integration
- Integration of digital twins
- Testing and commissioning supportSafety approvals
- Ramp-up management
- Performance monitoring and optimization
The result is a stable, autonomous 24/7 operations
Your benefits
Dark warehouses are more than an automation; they are a strategic competitive advantage.
With our integrated approach, we combine process, technology, and building design into a robust system. This approach provides:
- Reduction in Operating Costs: 20–30% reduction in logistics operating costs, depending on the project, along with a more stable cost structure even with fluctuating volumes
- Higher Productivity and System Performance: 20–40% higher overall equipment effectiveness, 15–35% shorter throughput times, and up to 30% greater throughput capacity within the same footprint, depending on the project
- Optimized Inventory and Reduced Capital Tie-Up: 10–30% lower inventory levels, reduced tied-up capital, improved liquidity, and lower safety stock levels, depending on the project
- Scalability Without Linear Cost Increases: Rapid response to market fluctuations, predictable growth, and no structural bottlenecks during volume surges
Let's talk.
We're happy to help.