Automation and robotics in intralogistics: trends, challenges and opportunities

Robotics meets intralogistics: paving the way for economic progress

The intralogistics industry is currently undergoing a profound transformation, characterized by increasing automation and the use of innovative robotics and AI solutions. Despite a weakening German economy, this sector demonstrates significant growth potential and technological advancements. While some companies, such as Schwingshandl automation technology, are experiencing above-average growth, many established businesses are struggling to integrate new technologies into their existing structures. The following discussion examines the current developments, challenges, and opportunities of automation and robotics in intralogistics, as well as their significance for the future viability of companies in this sector.

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Current developments and innovations in intralogistics

The intralogistics industry is currently experiencing a remarkable surge in innovation, driven by leading providers such as Viastore, Agilox, and Knapp. These companies are focusing on intelligent automation solutions that prioritize efficiency, flexibility, and scalability. Viastore recently expanded its pallet storage solutions portfolio with innovative pallet shuttles that enable companies to maximize their storage capacity – even in irregularly shaped warehouse layouts. With a payload capacity of up to 1,500 kilograms and an operating temperature range of -30 to +50 degrees Celsius, these fully automated systems offer versatile applications, including in deep-freeze environments. Their compact design reduces the space required for travel paths, allowing for more load units and optimal use of warehouse space.

In the field of autonomous mobile robots (AMR), Agilox has established itself as a leading provider with an impressive global market presence. With over 1,800 autonomous mobile robots in operation and renowned customers such as Siemens, BMW, Bosch, and Daimler, the company has firmly established itself internationally. To further drive global growth, Agilox introduced a new dual CEO leadership team, consisting of David Niedermaier and Dirk Erlacher, effective April 1, 2025. This strategic decision underscores the company's expansion, which already includes offices in Europe, the USA, and China, and employs more than 250 people. Dirk Erlacher's international experience, gained previously as CEO of Agilox APAC, where he led the expansion into the Asian market, will further strengthen the company's global strategy and operational efficiency.

AI-powered robotics is also gaining increasing importance, as demonstrated by the collaboration between Knapp and Covariant. At the heart of this partnership is the Pick-it-Easy Robot picking solution, developed approximately five years ago with Covariant's AI-powered vision system. This innovative solution enables the automated handling of individual items, for example, for high-performance order picking or the fully automated transfer of goods to pocket sorting systems. Thanks to the use of AI, robotics in logistics applications can handle a wider range of items with varying sizes, surface properties, or packaging. The technology has proven its worth in both new warehouse structures and for optimizing existing facilities and is currently used by 26 Knapp customers across various industries worldwide.

Technological advances are changing the intralogistics landscape

Intralogistics is undergoing a profound transformation, driven by innovative technologies such as autonomous mobile robots, digital twins, artificial intelligence, and humanoid robots. These technological advancements mark a new era in which flexibility and innovation are becoming crucial success factors. Automation is key to increasing efficiency in intralogistics, with autonomous mobile robots (AMRs) and automated guided vehicles (AGVs) revolutionizing material flows and enabling companies to manage complex logistics requirements more efficiently.

The variety of robots used in intralogistics is expanding rapidly, with leading providers like Magazino and KUKA developing versatile robotic systems ranging from mobile small parts warehouses to collaborative mobile robots. New robot types, such as autonomous forklifts for outdoor use or robotic tractors for yard operations, are continuously broadening the range of applications. Specialized systems like cleaning robots and drones are also gaining importance by seamlessly integrating into production processes and monitoring inventory levels in real time. Humanoid robots from companies like Figure AI and Agility Robotics could take on flexible tasks such as machine loading in the future, further expanding the spectrum of automated processes.

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Market development and economic framework

The economic environment for the intralogistics sector is currently challenging, but also shows signs of resilience and growth potential. Current forecasts from the "Logistics Experts" indicate that the logistics sector will contract by 0.1 percent in real terms in 2025, while nominal growth of 1.3 percent is expected. The 26 experts in the panel, representing various companies such as Audi, DB Cargo, KPMG, and the Otto Group, believe the downward trend may be at a turning point, even though the overall situation is still considered challenging. This development contrasts with the expected GDP growth and underscores the specific challenges facing the logistics industry.

Despite these challenging conditions, the intralogistics market is demonstrating remarkable resilience and growth potential. While the industry was valued at US$41.3 billion in 2022, experts anticipate annual growth of 8 to 10 percent until 2032. In this demanding environment, some companies are achieving above-average success through specialization and innovation. One example is Schwingshandl automation technology GmbH, a leading provider of customized intralogistics solutions, which has more than doubled its revenue in the last four years and generated over €45 million for the first time in 2024. The company expects revenue of around €50 million in 2025, demonstrating that growth is possible even in difficult times.

Schwingshandl automation technology GmbH operates in a specialized niche that is often too small and complex for highly standardized general contractors, delivering customized solutions for a wide range of industries – from food production and fashion to airport logistics and the automotive industry. This focus on niche markets and the ability to meet individual customer needs has proven to be a successful strategy in a highly competitive environment. The company has already prepared expansion plans for its planned further growth, underscoring its confidence in future market developments.

Challenges in implementing automation solutions

Implementing automation solutions in intralogistics presents numerous challenges that pose significant hurdles for many companies. A recent study by TMG Consultants, entitled “Automation and Digitalization in Intralogistics,” reveals a considerable need for improvement in this area and concludes: “Production good, intralogistics inadequate.” Particularly alarming is the fact that 63 percent of the surveyed companies have not automated their intralogistics at all or only to a limited extent, while another 22 percent have at least partially automated processes. Highly automated processes with integrated systems are found in just 11 percent of companies, and only 4 percent have reached the highest level of autonomous intralogistics. These figures illustrate the significant discrepancy between technological potential and its actual implementation in practice.

A major problem in automating intralogistics lies in the inadequate planning and analysis of current processes before the introduction of automated systems. Many companies overestimate the maturity level of their intralogistics and neglect a comprehensive analysis of their operations, leading to suboptimal integrations and inefficient systems. Other common errors include the lack of flexibility in automated systems, which cannot adequately adapt to changing circumstances or production conditions, and a lack of standardization in intralogistics processes, which hinders automation. These factors, coupled with insufficient training and onboarding for employees, often result in suboptimal use of the implemented technologies.

Integrating new technologies into existing operational processes presents another key challenge. Automated truck unloading at the loading dock, in particular, remains an unresolved issue, as the TMG study demonstrates. The technological integration of various systems demands a high level of expertise and meticulous planning, which overwhelms many companies. A strategic overview, sufficient project resources, and a sound market understanding are often lacking, leading to a degree of resignation and jeopardizing competitiveness through outdated intralogistics structures. These outdated structures not only result in inefficient processes but also in employee frustration and can weaken the company's market position in the long run.

The human factor in automated intralogistics

The shortage of skilled workers represents one of the biggest challenges for intralogistics, as an EHI study on "Success Factors of Modern Retail Logistics" shows, in which nine out of 13 companies surveyed cited recruitment as a key challenge. The logistics sector employs approximately 2.8 million people in Germany and operates as a service provider in an environment characterized by increasing dynamism, complexity, and unpredictability. Recruiting qualified staff is becoming increasingly difficult in the logistics sector under the conditions of the low-wage industry, while absenteeism due to illness and the turnover rate among young employees are comparatively high.

The required flexibility is currently mostly achieved through the use of temporary workers, but personnel measures are increasingly insufficient to compensate for short-term and unplanned fluctuations in performance. Competition for a limited labor supply is increasingly restricting this approach and intensifying the pressure on companies to find alternative solutions. While automation offers opportunities, it also requires appropriate training of existing employees to effectively utilize the new technologies. Finding the balance between technological innovation and human expertise remains one of the key challenges for the successful transformation of intralogistics.

Opportunities and potential of automation

Despite all the challenges, automation in intralogistics offers considerable opportunities and potential for companies. The use of innovative technologies enables significant efficiency gains and process optimizations, which can provide decisive advantages in today's highly competitive economic landscape. Automated systems like the pallet shuttle system from viastore enable extremely compact, multi-deep storage, leading to optimal utilization of available warehouse space. The shuttles are designed to be so compact that less space is required for travel paths, allowing for more loading units and maximizing warehouse capacity. This optimization of warehousing contributes significantly to increased overall efficiency and simultaneously reduces operating costs through better resource utilization.

Another significant advantage of modern automation solutions lies in their flexibility and scalability. The viastore pallet shuttle system, for example, is characterized by its modular design, which allows for flexible adaptation to existing building structures. With its brownfield-compatible architecture, the system can also be implemented in existing warehouses and tailored to existing floor plans, layouts, or roofs. Different layouts per level are possible, and the shuttles can independently change direction, making them particularly suitable for buildings with irregular floor plans. Additional shuttles can be easily integrated to increase throughput, while the racking system can be flexibly expanded to include more spaces, enabling easy scaling to meet the growing needs of the business.

Automation also offers significant competitive advantages that can be crucial in today's dynamic market environment. An EHI study shows that eleven out of thirteen retailers surveyed are planning concrete steps toward automation, while six intend to increase their use of robotics applications. Technological advancements are expected to enable companies not only to enhance their competitiveness but also to respond to the growing demand for fast and reliable deliveries. Particularly significant potential is seen in order picking, where solutions like Knapp's Pick-it-Easy robot are already being used successfully to relieve employees of monotonous routine picking tasks while simultaneously increasing precision and speed.

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Sustainability and improved working conditions through automation

In addition to its economic advantages, automation also offers significant opportunities in the areas of sustainability and workplace design. Modern automated systems, such as the pallet shuttle system from viastore, are characterized by lower energy consumption compared to other automation solutions, resulting in both ecological and economic benefits. More efficient energy use contributes to reducing the environmental footprint and supports companies in achieving their sustainability goals, which are becoming increasingly important today. At the same time, these systems offer maximum safety and reliability through redundant shuttle deployments and easy maintenance options during operation, minimizing downtime and ensuring business continuity.

Automation also leads to a significant improvement in working conditions for employees in intralogistics. By taking over monotonous, repetitive, and physically demanding tasks with robots and automated systems, employees can concentrate on more challenging and value-adding activities. This not only leads to greater job satisfaction but also to a reduction in work-related health problems and absenteeism. Robotic solutions like the Pick-it-Easy Robot from Knapp relieve warehouse employees of monotonous routine picking tasks, thus contributing to a more humane work environment. This improvement in working conditions can also help counteract the shortage of skilled workers by increasing the attractiveness of jobs in the logistics sector.

Future prospects and recommendations for action

The future of intralogistics will be significantly shaped by the continued expansion of automation and the integration of intelligent technologies. Intralogistics is undergoing a profound transformation, driven by innovative technologies such as autonomous mobile robots, digital twins, artificial intelligence, and humanoid robots. Cloud-based platforms improve efficiency, security, and scalability while helping companies use resources like energy more efficiently. These trends mark a new era in which flexibility and innovation are crucial success factors, and companies that resist this development risk falling behind.

However, implementing automation solutions requires careful planning and a strategic approach to avoid costly mistakes. A common error is that companies introduce automation without sufficient planning and analysis of their current processes and specific requirements. It is therefore crucial to conduct a comprehensive workflow analysis to optimally integrate the automated systems into the overall system. Equally important is ensuring sufficient flexibility in the implemented solutions to respond to future challenges and changing market conditions. Overly rigid automation can lead to bottlenecks and inefficient processes, ultimately causing more problems than it solves.

For companies looking to modernize their intralogistics, brownfield-compatible solutions are particularly important, as they allow integration into existing structures without requiring costly new construction. Systems like viastore's pallet shuttle system, with their brownfield-compatible architecture, can be implemented in existing warehouses and adapted to existing floor plans, layouts, or roofs. This enables a phased modernization and automation of intralogistics, better suited to the financial and operational capabilities of many companies. Knapp's Pick-it-Easy Robot picking solution has also proven its worth in both greenfield and brownfield environments for optimizing existing sites, thus offering flexible deployment options for diverse starting points.

The successful implementation of automation solutions in intralogistics depends significantly on the proper integration and training of employees. Insufficient training and onboarding can lead to the ineffective use of new technologies and prevent their full potential from being realized. It is therefore essential to allocate sufficient resources for employee training and continuous professional development and to actively involve employees in the transformation process. Only by combining technological innovation and human expertise can companies unlock the full potential of modern intralogistics solutions and optimally position themselves for the challenges of the future.

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Why the intralogistics market continues to grow despite declines

Automation and robotics in intralogistics offer enormous potential for efficiency gains, cost savings, and competitive advantages, but also present companies with significant challenges in implementation and integration into existing structures. The development of innovative solutions such as autonomous mobile robots, AI-supported picking systems, and flexible pallet shuttle systems is progressing rapidly, opening up new possibilities for optimizing logistics processes. At the same time, the reality in many companies still reveals a considerable need for improvement, as illustrated by the fact that 63 percent of the surveyed companies have not automated their intralogistics at all or only to a limited extent.

The current economic environment is challenging, with a projected real contraction of 0.1 percent in the logistics sector in 2025. Nevertheless, even in this difficult environment, there are success stories like Schwingshandl automation technology, which achieves above-average growth through specialization and innovation. Despite the current economic challenges, the intralogistics market as a whole shows considerable growth potential, with an expected annual increase of 8 to 10 percent until 2032. This positive development is driven primarily by increasing automation and the use of innovative technologies.

A successful transformation of intralogistics requires a strategic, holistic approach that equally considers technological innovation, process optimization, and employee training. Companies that meet this challenge will be able to strengthen their competitiveness, respond to increasing customer demands, and simultaneously create more sustainable and humane working conditions. The future of intralogistics lies in intelligent, networked, and flexible systems that seamlessly integrate into the company's overall structure and generate measurable added value. In this dynamic environment, those companies that are willing to invest in innovation, learn from mistakes, and continuously improve their processes will succeed.

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