Material Handling Automation for Existing Facilities: Why Brownfield Projects Are Gaining Momentum

Blake Bearden | 30 July 2025

A few years ago, a Midwest warehouse faced familiar pressures: limited space, rising labor costs, and growing demand for faster fulfillment. Rather than building new, they retrofitted their existing distribution center. By upgrading within their current footprint, they streamlined operations and gained flexibility without disrupting business.

Across warehouse, distribution, and manufacturing environments, companies are rethinking their approach to modernization. Brownfield projects—automation retrofits within existing facilities—are gaining traction as a practical, lower-risk alternative to greenfield construction.

Whether due to tighter budgets, uncertain economic conditions, or a desire to move quickly without adding square footage, leaders are seeking ways to do more with what they already own. In many cases, they’re finding that a smart retrofit delivers the operational improvements they need, without the time or capital required to start from scratch.

The Case for Brownfield Material Handling Automation

Across warehouse and distribution centers, as well as manufacturing environments, leaders are facing the same question: how do we stay competitive without overcommitting capital or delaying results? Automating your brownfield facility provides a flexible path forward, offering benefits that closely align with today’s business pressures.

Cost Control and Capital Efficiency

Building new requires significant capital for real estate, construction, and infrastructure. Brownfield projects alleviate this burden by focusing investment on equipment and systems, rather than on bricks and mortar. This approach supports incremental progress where automation is added in phases while maintaining budgeting flexibility.

Faster Time to Value

New builds often face long lead times due to permitting delays, delays from utility providers, construction delays, and supply chain constraints. Brownfield projects skip much of this, accelerating automation deployment. With known facility conditions, engineering teams focus directly on improvements, delivering faster results with less disruption. Brownfield retrofits can be delivered as early as 6-12 months compared to 18-24 months typical of greenfield construction.

Smarter Use of Space

Warehouse space comes at a premium, particularly in high-demand areas. Brownfield projects push strategic thinking about existing layouts, often uncovering underutilized zones or vertical opportunities. Whether installing AS/RS systems, reconfiguring picking areas, or consolidating zones, brownfield automation extracts more value from every square foot.

Sustainability Benefits

Retrofitting aligns with sustainability efforts by reducing construction emissions and preserving resources. Keeping buildings in service reduces material waste and energy consumption. For operations tracking ESG (environmental, social and governance) metrics, this enhances the value of brownfield investments.

Brownfield Automation Challenges and How to Overcome Them

Every automation project involves complexity, but retrofitting active facilities adds unique considerations. Unlike greenfield projects, brownfield initiatives require designing around existing infrastructure and ongoing operations.

Existing Facility Constraints

Floor space, ceiling height, column spacing, and dock configurations determine what's possible. Overcoming limitations starts with a thorough facility assessment. Simulation tools help evaluate material flow, and experienced integrators ensure equipment choices align with physical realities.

Solutions:

• Conduct detailed facility audits before design 
• Use simulation and layout modeling to maximize space utilization
• Prioritize flexible, modular material handling solutions, allowing for phased implementation

Minimizing Downtime

In live facilities, downtime carries a significant cost. Brownfield automation relies on phased cutovers, staging transitions in sections to maintain operations. Strategic scheduling during low-volume periods, combined with pre-testing, further minimizes disruptions.

Solutions:

• Plan phased rollouts to isolate work zones
• Schedule installs during low-volume periods
• Use system simulation to test designs before go-live

Legacy System Integration

Most brownfield projects involve integrating old and new systems. Whether it’s connecting new conveyor controls to an existing WMS or aligning robotic systems with older scanning equipment, software and controls integration is a critical focus area. Understanding current system limitations and identifying necessary upgrades helps avoid complications.

Solutions:

• Perform technology audits early in planning
• Identify opportunities for middleware or phased software upgrades
• Engage controls experts who can bridge new and existing infrastructure
• Ensure legacy system integration also considers any potential security vulnerabilities

Safety and Continuity

Construction in active facilities introduces risk. Clear communication, defined work zones, and safety planning are essential. Training teams ahead of go-live supports smooth transitions.

Solutions:

• Coordinate closely between engineering and operations teams
• Segment work areas to reduce safety risks
• Provide hands-on training during transitions
• Conduct a safety audit to ensure compliance to latest Federal and State OSHA compliance with legacy system integration

Best Practices for Successful Brownfield Automation Projects

Success requires more than good equipment. The best brownfield automation projects require strong planning, the right stakeholders, and teams that understand existing constraints.

Early Planning and Cross-Functional Input

Earlier involvement from operations, IT, and engineering improves outcomes. Each group brings critical knowledge about facility operations, pain points, and success metrics. Early alignment reduces surprises later.  Creating a strong cross-functional automation steering group is a sound practice to ensure input is collected across all involved divisions to avoid surprises later in the implementation.

Strong Project Partner

Brownfield projects present unique complexities related to live operations, legacy systems, and minimizing downtime. Experienced material handling automation integrators make measurable differences in project execution.

Scalability and Future Planning

Even focused projects benefit from forward thinking. Facilities change, volumes shift, expectations evolve. Building in flexibility—whether through modular automation, scalable software, or room to expand—helps ensure that today’s investment continues to deliver value.

When to Choose Brownfield vs. Greenfield Automation

Material handling automation isn’t just for new buildings. It’s accessible to any operation willing to work with their existing infrastructure. And in many cases, retrofitting is often the smarter choice.

Brownfield automation fits when:

• Operating in structurally sound older facilities
• The business case doesn't justify new construction costs
• Implementation timelines are tight, and flexibility is key
• Piloting automation before broader rollouts

If facilities meet basic requirements and challenges lie in outdated workflows rather than physical structure, retrofits may be the fastest, most cost-effective modernization path.

Success hinges on having the right plan and partner. Brownfield projects require thoughtful layout design, seamless system integration, and coordinated implementation to ensure smooth operations. The decision matrix below provides a comparative analysis of Brownfield vs. Greenfield projects against major decision-making criteria:

BROWNFIELD vs. GREENFIELD AUTOMATION DECISION MATRIX
Criteria	Brownfield Automation	Greenfield Automation
Upfront Cost	Lower—focuses on equipment, avoids real estate and major construction	Higher—includes land acquisition, construction and new infrastructure
Implementation Time	Faster—works within known conditions, avoids permit delays	Slower—requires permits, site development and construction
Risk	Lower—leverages existing systems and layout	Higher—unknown site variables, full new integration
Business Disruption	Minimal—phased implementation avoids full shutdowns	Total shutdown avoided during build, but operations start from zero
Scalability	Moderate—limited by existing infrastructure	High—built for future growth from day one
Customization	Constrained — must work around existing facility constraints	Fully customizable—blank-slate design flexibility
Sustainability	High—reuses structures, reduces material waste	Lower—new materials and construction increases environmental impact
IT / Controls Integration	Complex—must bridge old and new systems	Simpler—new systems designed to work together
Speed to ROI	Faster—quicker go-live enables faster realization of benefits	Slower—longer timeline before ROI is realized
Ideal When	Facility is sound, timeline is short, budget is tight	Long-term needs justify major investment and new infrastructure is required

 

At Bastian Solutions, we assess the suitability and requirements for the successful implementation of material handling automation in your brownfield facility. From initial modeling to final implementation and ongoing support, our team designs automation strategies that work within your existing infrastructure, enabling progress without requiring a restart.

Ready to explore possibilities in your existing facility? Contact a Bastian Solutions engineer to discuss your material handling automation goals.

Author: Blake Bearden