AutoStore System

Unlock High-Throughput Storage & Order Fulfillment with AutoStore

AutoStore is a powerful, high-density storage and retrieval system built for speed, accuracy, and efficiency. Its customizable, space-saving design maximizes storage capacity, accelerates picking, and scales easily without interrupting operations.

Perfect for fast-paced e-commerce, omnichannel, and 3PL operations, AutoStore keeps orders moving and customers satisfied. Cold chain configurations extend those benefits to grocery and healthcare environments, performing in temperatures as low as -13°F (-25°C).

Bastian Solutions custom designs AutoStore systems tailored to your goals, facility, and growth plans. When paired with our Exacta intralogistics software and complementary automation, AutoStore helps you create a seamless, fully automated fulfillment operation.

As a global AutoStore integrator, Bastian Solutions has seen repeated success with AutoStore installations both large and small.

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How the AutoStore System Works

The AutoStore system is comprised of 4 main components: a structural grid, delivery robots, storage bins, and operator workstations. Products are stored in stacked bins within the compact aluminum grid. When an item or case is needed, the system’s software directs a robot to retrieve the bin containing that product.

If the required bin is located beneath other bins, the robot temporarily stages the upper bins on the grid’s surface, retrieves the target bin, and then transports it to an operator workstation for picking. Another robot will return the staged bins to their original positions.

AutoStore can be integrated with additional picking and conveying technologies – pick to light, conveyors, goods to robot – for a fully automated order fulfillment solution.

Components:

Grid – aluminum structure in which bins are stored on top of each other.
Bin – unit in which products are stored, available in 3 bin heights (220mm, 330mm and 425mm) with moveable dividers for storage flexibility. Multiple bin heights can be used to maximize storage density.
Workstations – ports where bins are delivered to operators. Multiple workstation options are available to maximize task optimization, ergonomics, and system layout. The new VersaPort™ workstation streamlines inbound, picking, packing, and kitting workflows with built-in safety features and easy modular installation.
Robot – unit that transports bins throughout grid. Four robot types are available to accommodate various throughput needs and bin sizes (R5, R5+, R5 Pro, and R5+ Pro).
Controller – plans and executes all AutoStore activity, acts as traffic cop and troubleshoots errors to increase uptime.

Features & Benefits

Maximize Space Efficiency

Up to 60% space savings with ultra-high storage density
Modular grid fits around pillars and obstacles
Installs easily in low-ceiling buildings
Scalable capacity: add robots, workstations, and bins on demand with minimal downtime
Mix and match three bin sizes for flexible SKU storage and even more storage density

Increase Throughput

99.8% uptime for reliable 24/7 operations
Consolidate full case and piece picking into one system
Multiple ergonomic workstation options for faster picking
Adapts to seasonal demand automatically
Optimized bin distribution for SKU rotation

Reduce Costs

Low energy use with regenerative batteries
Operates without roof lighting
Reduces HVAC energy needs
Up to 50% faster picking vs. manual methods
Cuts labor costs with easy-to-learn workstations
Flexible Robots-as-a-Service (RaaS) model lowers upfront costs
Dedicated cold storage solutions reduce energy needs by up to 40%

Considerations

To find the most effective storage and picking solution for your operations, it’s important to consider:

Facility size, layout, and infrastructure (ex: slab thickness, obstacles to build around, fire protection requirements, floor flatness, etc.)
Product size and weight
Storage environment temperature requirements
Order volume and speed
Customer fulfillment expectations and peak season demands
Business growth forecast and objectives

AutoStore FAQs

What is AutoStore?

AutoStore is an automated storage and retrieval system that enables fast and efficient picking of both full cases and individual items. This high-density system utilizes robots to move bins in and out of storage and deliver them to workstations for picking.

The basic components of AutoStore include the grid, bins, robots, ports, and controller, all designed for easy integration, quick assembly, and built-in redundancy.

Can the Autostore system be expanded?

Yes, AutoStore is fully modular. You can expand by adding more robots, bins, grid modules, or operator ports with no disruption to operations.

This scalability enables businesses to quickly adapt to changing business needs.

Can AutoStore integrate with existing automation systems?

AutoStore can easily integrate with a variety of automation technologies including conveyor systems, pick-to-light, AI-powered picking robots like Bastian Solutions SmartPick™ and warehouse management software.

Software solutions play a crucial role in optimizing the performance of AutoStore systems, ensuring seamless operation and enhanced efficiency.

What are the requirements for installing AutoStore in a warehouse?

Considerations include the specifications of your existing facility and existing setup, as well as ceiling height, floor specifications, product size and weight, desired throughput, seasonal volume swings, fire protection requirements and future scalability. Autostore's smart shimming system reduces requirements for floor flatness without compromising performance. Updated fire protection design decreases installation costs up to 35%.

What is Pio by AutoStore?

Pio is a compact AutoStore solution designed for small and mid-sized businesses. It offers plug-and-play automation with flexible purchasing options including Robotics-as-a-Service (RaaS).

What goes into designing an AutoStore system?

Designing an AutoStore system involves assessing warehouse space, inventory types, and fulfillment goals. The grid is configured to maximize space and flow, and integrated with existing software and automation like conveyors. This tailored approach ensures efficiency today while allowing for future expansion.

AutoStore Resources

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AutoStore Videos

AutoStore Customer Success Stories

With over 100 successful projects, Bastian Solutions is recognized as one of the top AutoStore integrators in the world. We've helped customer of various sizes and across a variety of industries achieve their goals with AutoStore .