Layer Picking technology: transforming modern warehouse automation

As revealed in a recent interview published on Körber's website, layer picking solutions have transformed warehouse operations, with more than 700 layer pickers currently operating worldwide.

The logistics industry faces increasing complexity daily. Whether managing an FMCG warehouse or operating a 3PL facility, operations teams must handle an ever-expanding number of SKUs. In their recent interview, Körber's experts René Kahr and Jan Kristensen discuss how these evolving challenges are driving the need for more sophisticated warehouse automation solutions.

During the conversation, Kahr reveals how a distinctive customer request from a whisky producer sparked the development of an innovative gripper tool. This advancement, as he explains, helped "democratize a great variety of different goods" and created what he describes as a "blue ocean market" in the industry.

The innovation behind modern Layer Picking

Modern layer picking systems represent versatility in warehouse automation. Through an advanced combination of air and vacuum technology, these systems efficiently handle a diverse range of products - from delicate yoghurt cups to substantial layers of PET bottles.

Key capabilities that distinguish these systems include:

• Processing capacity of up to 10,000 layers daily
• Operational temperature range from -28°C to +40°C
• Coverage of 98% of food retail products
• AI-powered monitoring for increased efficiency and uptime
• Automated rainbow and sandwich pallet construction

Meaningful benefits for warehouse operations

For warehouse operations, three essential factors typically drive decision-making: efficiency, cost management, and sustainability. Layer picking technology delivers substantial improvements across all these areas:

Enhanced operational efficiency

Modern layer picking systems eliminate the need for manual heavy lifting and repetitive movements, allowing staff to focus on higher-value activities while maintaining continuous 24/7 operation.

Environmental and economic advantages

These systems offer impressive sustainability benefits through energy-efficient design, including power regeneration capabilities. Their durability - with systems operating reliably for over two decades - ensures long-term value.

Advanced adaptability

The integration of AI and machine learning enables these systems to continuously improve their handling capabilities. They readily adapt to new packaging requirements, including eco-friendly alternatives, ensuring long-term viability.

The future of warehouse automation

The evolution of warehouse automation continues to accelerate, with several key developments emerging:

• Advanced AI decision-making capabilities
• Flexible solutions for various facility sizes
• Enhanced energy efficiency systems
• Improved product handling capabilities
• Integration with autonomous mobile robots

The strategic perspective

The logistics industry continues to evolve rapidly, with increasing customer demands, workforce challenges, and efficiency requirements. Modern layer picking systems represent more than automation - they offer a comprehensive solution for transforming warehouse operations, helping businesses meet next-day delivery expectations while maintaining consistent performance levels.

Learn more about layer picking technology and read the full interview with René Kahr and Jan Kristensen.