An automated warehouse is a logistics facility in which the movement, storage, and flow of goods are managed by automated systems integrated with control software. Its main benefits include increased storage capacity — achieved by reducing aisle widths and load clearances — improved traceability, and a significant reduction in operational errors. At AR Racking, we design storage structures prepared for integration with automated solutions, tailored to the operation and efficiency objectives of each project.

An automated warehouse operates through the integration of structure, automation, and software. Goods are identified, automatically located according to defined criteria, and retrieved when required by the operation. To ensure safety, continuity, and performance, the storage structure must be designed specifically to meet the structural deformations and installation tolerances demanded by the automated system. AR Racking provides that structural foundation with specialist engineering and bespoke design.

Automated storage systems can be adapted for pallets, boxes, or light loads. The most commonly used solutions include AS/RS stacker crane systems for pallets or containers; miniload systems for boxes and trays; pallet shuttle systems for high-density compact storage; and AGVs or autonomous mobile robots (AMRs) for flexible goods movement. The most appropriate solution depends on the type of load, the required throughput, the number of SKUs, and the space available.

Yes. Warehouses with a very high degree of automation exist, in which the receipt, storage, and retrieval of goods takes place with minimal human intervention — limited to exceptions, maintenance, and supervision tasks. The degree of automation can be modular: it is possible to start with a semi-automated solution and progressively increase the level of automation as operational needs and return on investment justify the investment.

An automated warehouse focuses on executing physical goods movements automatically. A smart warehouse additionally incorporates connectivity, traceability, real-time analysis, and AI-driven decision-making tools. In practice, a smart warehouse goes beyond automation by using data intelligently to optimise processes, predict maintenance needs, and improve operational decisions in real time.

Before implementing an automated warehouse, it is essential to analyse the load type, rotation frequency, number of SKUs, available space, goods flow patterns, budget, and medium-to-long-term operational projections. AR Racking carries out a technical pre-study for each project to assess these factors and define the most appropriate storage solution and level of automation.

Unlike a manual warehouse, a robotic system requires millimetre-level manufacturing and installation tolerances, as well as defined structural deformations under load. Even small deviations can cause the automated equipment to malfunction or enter a safety shutdown. AR Racking’s engineering team calculates the structure to the precision required by the automation equipment specified for each project.

Absolutely. Automated warehouses are a highly effective solution for cold storage, as they minimise door openings, reduce the exposure of personnel to low temperatures, and allow compaction to maximise the refrigerated volume. AR Racking designs structures for cold store and deep-freeze automated environments, specifying materials and coatings appropriate for the operating temperature and humidity conditions.

We carry out a comprehensive analysis that includes the unit load type, the cycle speed of the robotic equipment, the operating environment, the applicable regulatory standards, the permitted structural deformations, the seismic requirements of the project location, and the interface dimensions of the automation equipment. All of these factors are incorporated into the structural design to ensure compatibility and long-term reliable performance.

Thanks to our Traceability 4.0 system, every structural component carries a unique identifying mark. In an automated environment, this means that any maintenance intervention, component replacement, or structural audit can be completed with absolute certainty that the replacement part is compatible with the original design. This reduces unplanned downtime and provides full traceability of the installed structure throughout its entire service life.

Automated warehouse systems offer UK logistics operations a combination of higher throughput, reduced labour dependency, improved inventory accuracy, and better use of vertical space. In the context of rising labour costs, increasing SKU complexity, and the growth of e-commerce order volumes, automation can deliver a measurable return on investment by reducing picking errors, minimising product damage, and enabling 24/7 operations. AR Racking designs the structural framework for automated systems — including AS/RS, pallet shuttle systems, and miniload solutions — to the tolerances required by the automation equipment. Each project is engineered to integrate with the client’s warehouse management system (WMS) and operational workflow.