AutoStore boosts Arvato UK warehouse capacity by 30%

AutoStore and Arvato have expanded an automated storage system at Arvato's Hams Hall logistics site near Birmingham, increasing its capacity by more than 30 percent as demand grows in the UK market.

The project extends an AutoStore grid that Arvato first installed at the facility in 2023. The two companies worked with Swiss-based system integrator Kardex on the upgrade, which was completed in a little over three months.

The expanded system now uses 165 AutoStore R5 robots. They manage 87,600 storage bins, an increase from 65,000 bins previously, and support close to 1.2 million stored units.

Arvato reported that the automation has lifted throughput during peak periods to more than 26,000 orders per day. The company said this represents a 53 percent improvement compared with manual picking processes.

UK growth focus

The investment comes as Arvato targets further growth in the UK, where it runs supply chain and eCommerce services for international brands. The Hams Hall site serves clients across business-to-business and direct-to-consumer channels.

AutoStore said the project demonstrates how its automated storage and retrieval technology scales in live warehouse operations.

"This expansion shows how AutoStore technology supports fast scalability and high-performance fulfillment in live operations," said Frode S. Robberstad, President, EMEA, AutoStore.

The Hams Hall AutoStore system went live in August 2023, which Arvato described as the fastest implementation in its history.

"Since launching the AutoStore system in August 2023, we've significantly boosted productivity, scalability, and service quality," said Steven Pitt, Head of Operations at the Hams Hall site. "The compact design and automation have maximized warehouse space while reducing costs - helping us onboard new clients faster and with greater efficiency."

New client onboarded

Arvato said the latest expansion followed the onboarding of a new international customer. The client is a technical athletic apparel brand that requires rapid and reliable fulfilment in the UK.

The company has integrated AutoStore with its own warehouse control software, which manages and orchestrates the automated processes on site.

"The AutoStore system provides the flexibility and reliability required to support Arvato's growth in the UK market," explains Tim Godejohann, Project Lead Logistics Engineering at Arvato. "Integrating it through our own Warehouse Control System gives us maximum flexibility and short implementation timelines. This adaptability allows us to meet every expectation from our clients seamlessly."

Three-way collaboration

AutoStore and Arvato worked with Kardex on both the original installation and the new phase of the project. Kardex is one of AutoStore's long-standing partners and acts as system integrator on projects across multiple regions.

The companies said the collaboration at Hams Hall reflects a wider strategy of combining storage robots, software and integrator expertise across different industries.

"Our collaboration with Arvato on the Hams Hall project, supported by system integrator Kardex, reflects our shared commitment to delivering intelligent, high-performance fulfillment solutions that help businesses scale efficiently and meet growing market demands," said Robberstad.

Automation strategy

Arvato has positioned the Hams Hall investment within a broader plan for its UK logistics network. The company operates a range of automated and manual fulfilment centres serving sectors including retail, consumer goods and technology.

Its management has described automation as a central element of its long-term strategy for clients seeking faster delivery times and better use of warehouse space.

"With our investments in technology, we take a strategic approach to optimize and shape supply chains for our clients," said Dennis Schmitz, Managing Director of Arvato in the UK. "The expansion of the AutoStore system underlines the strong momentum we're seeing in the UK market and our commitment to keep building on it."

AutoStore said it now has more than 1,850 systems installed across over 60 countries. The company continues to work with partners and integrators on further warehouse automation projects in both B2B and B2C fulfilment.