536 Bins/Hour Mega Warehouse Automation Case | 33 ACR + 18 AMR Intelligent ASRS System

This project demonstrates a next-generation high-throughput automated storage and retrieval system (ASRS) combining 33 ACR robots and 18 AMR robots.

The system is designed for large-scale e-commerce and distribution environments where high SKU complexity, fast order fulfillment, and 24/7 operation are required.

With a peak throughput of 536 bins per hour, this solution significantly improves warehouse efficiency while increasing storage density and reducing manual labor dependency.

Modern logistics and e-commerce warehouses face increasing operational pressure:

High SKU complexity (thousands of SKUs)
Rapid order fulfillment requirements
Labor shortage and rising labor costs
Inefficient manual picking operations
Warehouse space limitations
Order accuracy requirements

Traditional warehouse systems struggle to handle both high throughput and high density storage simultaneously.

This project implements a hybrid automation strategy combining ACR + AMR + intelligent control system.

Key advantages:

ACR robots handle high-density rack storage and retrieval
AMR robots manage flexible intra-warehouse transport
Intelligent system allocates tasks dynamically
Reduced human intervention in core operations
Fully scalable warehouse architecture

This hybrid model enables both high storage density and high operational flexibility.

Step 1: Incoming Goods Reception
Goods are received and scanned into the system for identification and sorting.

Step 2: AMR Transport Allocation
AMR robots automatically transport goods to assigned warehouse zones.

Step 3: ACR Storage Operation
ACR robots perform:
Bin lifting
Deep rack storage
Automated slot assignment

Step 4: Intelligent Storage Management
System dynamically optimizes:
Storage location
Retrieval priority
Warehouse balancing

Step 5: Order Picking Execution
When orders are triggered:
ACR retrieves bins
AMR transports bins to packing zones

Step 6: Sorting & Packing
Goods are grouped and prepared for outbound shipment.

Step 7: Dispatch & Outbound
Finished orders are sent to shipping zones automatically.

This project represents a new generation of intelligent warehouse automation systems.

Unlike traditional ASRS systems that focus only on storage density, this solution integrates robotic mobility, dynamic scheduling, and real-time warehouse intelligence to maximize both efficiency and scalability.

It is designed for high-demand logistics environments where speed, accuracy, and flexibility are equally important.

• 1️⃣ High Throughput Performance
• The system achieves 536 bins/hour, enabling fast order processing for large-scale operations.
• 2️⃣ Hybrid Robot Architecture
• ACR handles vertical + rack storage
• AMR handles horizontal transportation
• This separation improves efficiency and reduces system bottlenecks.
• 3️⃣ High Storage Density
• 46,000 bin capacity
• Dual-deep rack design increases density by 15%
• 4️⃣ Smart Warehouse Intelligence
• 3D SCADA system enables:
• Real-time monitoring
• System visualization
• Predictive scheduling
• 5️⃣ 24/7 Autonomous Operation
• With automatic charging systems, robots operate continuously without downtime.

Phase 1: System Design (2–4 weeks)
Warehouse layout + robot allocation planning

Phase 2: Manufacturing (6–10 weeks)
Racking system + robot production

Phase 3: Software Integration (3–6 weeks)
WMS + WCS + SCADA system integration

Phase 4: Installation (2–4 weeks)
On-site assembly and system setup

Phase 5: Commissioning (1–2 weeks)
Testing, optimization, and go-live support

Operational Value:
Higher warehouse throughput
Reduced human labor dependency
Faster order fulfillment
Improved accuracy and traceability
Continuous 24/7 operation capability

Strategic Value:
Scalable warehouse architecture
Future-ready automation system
Multi-warehouse coordination capability
Reduced operational risk

Financial Value:
Lower long-term labor cost
Higher warehouse utilization efficiency
Faster ROI through throughput optimization

This 33 ACR + 18 AMR mega warehouse system demonstrates how modern logistics operations can achieve high throughput, high density, and full automation simultaneously.

It is especially suitable for:

E-commerce fulfillment centers
Third-party logistics (3PL)
Large distribution hubs
High SKU complexity warehouses

Before designing a similar system, key factors must be evaluated:

✓ Warehouse size and structure
✓ SKU quantity and turnover rate
✓ Throughput requirement
✓ Automation level
✓ Expansion strategy

If you are planning a smart warehouse or ASRS automation project, we can help you design the system, simulate throughput, and estimate total investment.

536 Bins/Hour Mega Warehouse Automation Case | 33 ACR + 18 AMR Intelligent ASRS System

This project demonstrates a next-generation high-throughput automated storage and retrieval system (ASRS) combining 33 ACR robots and 18 AMR robots.

The system is designed for large-scale e-commerce and distribution environments where high SKU complexity, fast order fulfillment, and 24/7 operation are required.

With a peak throughput of 536 bins per hour, this solution significantly improves warehouse efficiency while increasing storage density and reducing manual labor dependency.