Going Green with Warehouse Automation
Guest blog post by MHI member Cimcorp
Investments in warehouse automation are on the rise, as companies aim to boost efficiency, alleviate labor issues, and reduce costs. While these goals are undoubtedly driving the adoption of advanced order fulfillment technologies, they’re not the only factors in the decision to automate.
Another important, yet often overlooked, reason to adopt automation? Protecting the planet.
Sustainability is a growing imperative across the supply chain. When it comes to distribution, automation is helping companies tackle some of their biggest environmental challenges. This includes:
1. Energy consumption
Traditional warehouses and distribution centers (DCs) require substantial amounts of energy to operate. Usually large in size, these facilities need to keep lights on, plus heating or cooling running, for employees as they work. They also need to power heavy machinery that consumes a lot of energy.
Automation can significantly reduce a facility’s energy needs. Automated order fulfillment solutions can manage each step products take through the facility, optimizing overall material flow for maximum efficiency and minimal energy usage. All robots are precisely controlled by intelligent software, eliminating any unnecessary movements.
Automated systems can operate 24/7 in a lights-out environment with minimal human involvement, significantly reducing the need to expend energy. Additionally, some automated systems utilize high-density storage that requires half as much space as a traditional setup. Companies can handle more products within a much smaller facility footprint. Smaller facilities, of course, require much less energy to light, heat, and cool.
When it comes to automated systems themselves, today’s storage and order picking systems are designed for low energy consumption. Take gantry-style robots for example. Made from lightweight, durable aluminum, these systems can move precisely, accelerate quickly, and handle multiple crates or cases at the same time—resulting in much fewer movements and lower energy usage than other types of systems. Plus, some gantry-based systems incorporate regenerative braking technology, which allows them to recover and feed approximately 30% of energy back to the power grid.
2. Material waste
Waste is a significant issue across the supply chain that causes both economic and environmental repercussions. Material waste is generated at every stage—including scrap and defective products during manufacturing and spoiled items during distribution.
Automation can eliminate inefficiencies in areas that lead to waste, saving companies money and supporting their sustainability goals. In manufacturing, material handling automation can efficiently move and track materials and products between stages of production. Tire manufacturers, for example, are leveraging automation to deliver the right materials to the right machines at the right time, which prevents delays, bottlenecks, and unnecessary scrapping of materials. If any defective materials are detected at any point, manufacturers can track and trace individual components to avoid scrapping the whole inventory.
During distribution, automated storage and order picking solutions can eliminate bottlenecks and errors through rapid and accurate product handling. This means very short lead times—which is particularly important for facilities that handle perishable food like fresh produce, baked goods, and dairy products. Perishable food products can reach store shelves faster than ever before, minimizing the change of premature spoilage and maximizing shelf life. Food will last longer in consumers’ homes, rather than ending up in a landfill.
3. CO2 Emissions
Ground transportation is a key part of the supply chain, moving goods from producers to distributors to retailers. However, delivery trucks are a significant source of CO2 emissions. According to The Center for Climate and Energy Solutions, the transportation sector is the largest source of U.S. greenhouse gas emissions. Medium- and heavy-duty vehicles, including tractor-trailers and delivery trucks, produce about 26% of those transportation emissions.
Order-fulfillment automation can create efficiencies within DCs that result in lower emissions out on the road. Managed by a Warehouse Control System (WCS), automated solutions can build outbound orders to be route friendly, enabling truck drivers to take the most efficient routes. The solutions can also load and efficiently organize pallets within delivery trucks to optimize the use of available space. Route optimization means fewer miles are driven, and load optimization means fewer vehicles are needed. The result? Less exhaust fumes and less pollution overall.
Ready to explore eco-friendly automation?
When investing in automation, businesses should select a solution that not only supports sustainable practices, but also meets their unique requirements and goals. Here, the right automation provider can make all the difference. An experienced provider can share best practices they’ve learned and identify the ideal automation strategy for achieving sustainability goals and overcoming operational challenges. With the right partner and solution, you can adopt supply chain practices that are good for the planet and good for business.
