Robotic Buffering

Robotic Sequencing Solutions That Optimize Floor Space and Operations

As SKU variation, labor costs and real estate prices rise, robotic buffering systems offer companies a dynamic solution that reduces operational spend and layout constraints. Automating the process of sequencing and storing partial orders frees labor to perform more meaningful tasks, while improving order accuracy and delivery times.

With robotic buffering, consolidating multiple products for an order eliminates the need for expensive and expansive infrastructure like ASRS (automated storage and retrieval systems) or fixed and inflexible solutions like large-scale industrial racking. Bastian Solutions engineers can review your operations and determine the best robotic solution to meet your business needs. 

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How Robotic Buffering Works

Robotic queuing of products works best when integrated with other material handling equipment, creating a fully automated system. For fulfillment operations, orders waiting to be shipped are sent to the robotic cell via an infeed conveyor system from upstream equipment, such as a GTP (goods to person) solution. The robot equipped with a custom EoAT (end of arm tool) will safely place the product to a storage location inside nearby shelving in surrounding area around the robot work envelope. The design is scalable to meet existing facility footprints and allows the buffer to handle a wide range of product shapes and sizes.

Once all of the product for an order has reached the buffer, the robot can either palletize the products or send them to the downstream conveyor for further processing. Seamless integration with WES (warehouse execution system) enables product visibility as it moves through the system, proper product routing based on order details and accurate inventory tracking. The buffer allows the software system to utilize the end user’s business rules to sequence outbound product flow. Common requirements include reverse stop sequencing and store planogram pallet build sequencing.


Features & Benefits

  • Allows for 24/7 automated operations
  • Increases order accuracy, improving customer satisfaction
  • Precise and safe handling for a wide variety of product shapes and sizes including cases, totes, trays, pails, bins, ties and  heavy items
  • Design flexibility to fit new and existing facilities
  • Optimizes upstream and downstream material handling equipment
  • Reduces labor dependence and costs
  • High system uptime and reliability
  • Modular and scalable solution that adapts to business growth
  • Redundant buffer cells remove single point of failure and safeguards against cycle interruptions
  • Improves employee and product safety


When deciding whether a robotic buffering system could work for your operation, it’s important to consider the following factors:

  • Labor availability and costs
  • Product size, shape, weight and packaging
  • Number of storage locations and SKUs handled in the system
  • Facility layout and available footprint
  • Robotic reach, payload, speed
  • Compatibility with existing systems and technologies
  • Warehouse environment (ambient, freezer, etc.)
  • Factory acceptance testing (FAT) ensures our solution meets your standards

Technologies & Specifications

Robotic sequencing systems typically consist of the following technologies:


See More Solutions


Robotic Integration Services


Robotics Capabilities Brochure

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