Podcasts Archives - Material Handling Wholesaler

Smart Glasses for Warehousing: Simplify Warehouse Workflows

Mon, 11 May 2026 16:24:10 +0000

In this episode of The New Warehouse Podcast, Kevin Lawton catches up with Robby Moss of Vuzix. The conversation explores how Vuzix is bringing smart glasses and guided workflows into warehouse operations through hands-free technology and lightweight user experiences. The discussion covers everything from pick-and-pack validation to workflow analytics, remote maintenance support, and the role of smart glasses in helping warehouse teams reduce friction and improve visibility across operations. Building Smart Glasses Around Warehouse Reality Warehouse technology often fails when it adds friction to the job. Vuzix is taking the opposite approach. Instead of overwhelming workers with screens and complexity, the company focuses on making workflows feel more natural. Moss explained that simplicity is central to adoption. “You don’t have to go so far and make it complex. You wanna make it simple.” That philosophy shapes both the hardware and software experience. He also emphasized, “Our motto is to stay out of the way of the work.” The technology focuses heavily on hands-free execution. Moss described the goal clearly when he said, “We’re giving you hands-free, eyes up… and you’re just doing the work, looking where you’re looking, and we’re taking care of the rest.” Ideally, Vuzix wants the technology to fade into the background rather than dominate the workflow. Guided Workflows Extend Across the Warehouse Vuzix is not limiting smart glasses to a single workflow or department. Instead, the company is positioning the platform across inbound, outbound, maintenance, and inventory-related processes. Moss explained, “Any workflow that you really wanna drive, hands-free use… using their hands to pick up boxes and different things like that. That’s an ideal candidate.” The new pick-and-pack validation program announced at MODEX is designed to help operators evaluate the technology before committing to larger deployments. The kit includes an M400 or LX1 device, accessories, demo workflows, and Mobile Edge software. Users can test workflows such as pick assist, pack assist, pallet building, bin audits, goods receipt, barcode scanning, and OCR text scanning in less than 2 minutes. This creates faster troubleshooting without requiring specialists at every facility. Demoing the M400 Smart Glasses from Vuzix for Warehouse Operations Real-Time Visibility Creates New Operational Insights Vuzix is using its Insights software to capture workflow behavior in real time, giving leaders more immediate awareness of what is happening on the floor. Moss explained, “The ability to see certain types of analytics going forward… what kind of behavior do I have on the floor, where people are in a process, and I can capture all the behaviors and transactions from that device in real time.” That visibility is not just about monitoring activity. It also creates opportunities to improve training and identify friction points inside workflows. Moss noted, “If somebody’s quitting a process. So, is there something they didn’t learn or understand about the process? And we can adjust training and things like that.” Adoption remains one of the biggest challenges for wearable technology. Moss acknowledged that directly, saying, “Change management is a huge question. When related to adoption, because you want your workers to be productive, you want them to be comfortable.” Simple, effective solutions like this ultimately determine how quickly they move beyond the early adoption stages in warehousing. Key Takeaways Vuzix is positioning smart glasses as a hands-free workflow tool for warehousing and logistics. The company’s “stay out of the way of the work” philosophy emphasizes usability and adoption. The pick-and-pack validation program allows operators to test workflows before full integration. Demo workflows include pick assist, pack assist, pallet building, goods receipt, OCR scanning, and bin audits. Vuzix sees maintenance and remote support as strong use cases for smart glasses. The New Warehouse Podcast Smart Glasses for Warehousing: Simplify Warehouse Workflows

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EPG Aura Brings AI Into Warehouse Execution

Mon, 11 May 2026 13:19:58 +0000

Live from MODEX 2026, Kevin chats with the EPG team. Jett Chitanand, President of EPG USA, and Jason Wojtal and Ryan Absil discuss how AI in warehouse operations is evolving beyond dashboards and automation hype. Together, the demos demonstrate how AI and workforce technology are increasingly integrated into modern operations. AI Warehouse Operations Focus on Real Problems EPG took a different approach to AI at MODEX, focusing on operational friction within the warehouse. Chitanand explained that the company’s goal is practical execution, not AI for the sake of AI. As he put it, “We are focused on solving real-life problems inside the warehouse.” EPG Aura sits on top of warehouse systems and connects workflows, documentation, and operational processes into one AI-powered environment. During the demo, Wojtal showed how Aura could scan damaged delivery paperwork, recognize the information, and automatically process it into the system. He explained, “With our solution, our image recognition is about 95%.” The platform also integrates conversational AI into workflows. Chitanand described how operators can interact with the system naturally, saying, “We can scan it, and then say, or even talk with it, just like you talk with ChatGPT.” EPG Aura Expands Warehouse Visibility One of the more interesting demonstrations involved intelligent video analysis. Aura analyzes warehouse video streams in real time and identifies exceptions that leaders might otherwise miss. The system can monitor dropped cartons, dwell time, overcrowding, missing safety vests, and pallet activity. Wojtal described the functionality simply: “It’s an extra set of eyes for you there.” The key difference is customization. Users define what matters operationally. Aura then continuously monitors for those exceptions. Wojtal explained, “You ask what alerts you want, and it’s in plain text.” That flexibility extends into orchestration workflows as well. During one example, Aura detected that a carrier ETA had shifted significantly and identified five orders at risk of missing SLAs. Instead of forcing managers to use multiple systems, the platform automatically generated recommended actions. Wojtal noted that Aura is “constantly analyzing what’s happening” and “gives you recommended actions.” Importantly, operators still stay in control. Wojtal emphasized, “It won’t do anything unless you say, yes, take action.” That human-in-the-loop model may become one of the most important themes in AI warehouse operations moving forward. Gamification Brings Engagement to Voice Picking EPG also showcased new gamification capabilities within Lydia Voice. The concept introduces gaming mechanics into warehouse picking workflows through leaderboards, badges, rankings, coins, and audio-based feedback. Ryan Absil explained the strategy clearly: “Gamification is bringing context of gaming elements into Lydia’s voice.” The idea is not simply entertainment. EPG sees gamification as a way to improve motivation and retention in physically demanding warehouse environments. Chitanand explained, “Warehouse jobs are so demanding, and the workers are, you know, you could suffer from low motivation.” The Lydia system provides real-time audio feedback during picking workflows. Workers hear updates when they earn coins, increase productivity, or move to higher-ranking tiers. Absil said the larger goal is sustained engagement over long shifts. He explained, “The goal of gamification is to take a repetitive task over again over a long period of time and make that more enjoyable for the user.” That strategy may resonate especially with younger generations of the workforce, already accustomed to digital rewards and gaming environments. Key Takeaways EPG won a best product award at LogiMAT for Aura and received an MHI Innovation Award nomination for Lydia’s gamification features EPG Aura combines warehouse visibility, workflow orchestration, and AI-driven recommendations into one operational environment The platform generates recommended operational actions while keeping humans in control of execution decisions. Lydia Voice gamification introduces leaderboards, rewards, rankings, and audio feedback into warehouse picking workflows. EPG partnered with NVIDIA to support Aura’s observer use cases The New Warehouse Podcast EPG Aura Brings AI Into Warehouse Execution

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AI Forklift Platform: Redefining the Operator Experience

Wed, 06 May 2026 13:10:09 +0000

Welcome to this episode of The New Warehouse Podcast. Kevin chats with Bill Pedriana, President of Noblelift North America, live from MODEX 2026. Noblelift, a global manufacturer of lithium-powered lift trucks, is introducing a new wave of innovation. The conversation centers on the launch of the Omega and Hero platforms, with a strong focus on AI integration and operator enablement. Pedriana shares how Noblelift is rethinking the forklift, not just as equipment, but as an AI forklift platform designed to improve productivity, safety, and workforce performance in modern warehouse environments. AI Forklift Platform Shifts the Role of Equipment The biggest shift is not the hardware. It is how the forklift is positioned in the operation. Pedriana explains that Noblelift is moving beyond traditional equipment thinking. “There’s really nothing like this today, so we’re launching the first AI platform on a forklift.” That shift turns the forklift into a point-of-use technology layer. It is no longer just moving pallets. It collects data, guides operators, and improves decision-making in real time. This aligns with a deeper insight into cost structure. “The human operator is 75% of the cost of the human machine system… Only 25% of the cost is the machine.” As a result, the strategy becomes clear. Instead of optimizing the machine alone, Noblelift is investing in the operator. The goal is to improve productivity, safety, and skill development through embedded AI and real-time feedback. Empowering Operators with Real-Time AI Coaching According to Pedriana, “The traditional forklift is dead.” Enter the Omega. The Omega is “The first electric truck you never have to plug in.” The platform introduces agentic AI directly into the forklift. This allows the system to learn driver behavior and provide ongoing coaching. Pedriana describes how this changes daily operations. “Using agentic AI at the point of use… really drives the productivity, safety, and capability of an operator.” The platform tracks safety, productivity, and technique. It also introduces gamification, leaderboards, and performance insights. These tools help operators improve continuously, not just during onboarding. The impact compounds quickly. “The productivity benefit pays for everything… including the truck.” There is also a strong training implication. Instead of waiting years to develop top talent, the system accelerates learning curves. This matters in a market where skilled labor is harder to find and retain. Human-in-the-Loop Automation Outpaces Full Autonomy While automation remains a key trend, Noblelift is taking a different stance. The focus is not on removing the operator. It is enhancing them. Pedriana makes this clear. “Full auto is hard.” Instead, the Omega enables a hybrid model. Operators can command AGVs and AMRs through voice. They act as orchestrators rather than just drivers. This creates a force multiplier effect across the warehouse. Pedriana believes this approach will outperform full automation in many environments. “Keeping the human in the loop and giving the human tools like this agentic AI platform… outperform full automation.” This also opens the door for new workforce dynamics. As operators gain more control and capability, their role becomes more strategic. That shift could reshape how warehouses think about labor, training, and compensation. Key Takeaways Noblelift is positioning the forklift as an AI-powered platform, not just material handling equipment. Human labor represents roughly 75% of total system cost, driving a focus on operator enablement. The Omega introduces real-time AI coaching across safety, productivity, and technique. Gamification and performance tracking create continuous skill development. The platform enables voice-based orchestration of AGVs and AMRs for hybrid automation. Battery innovation allows extended runtime without a traditional charging infrastructure. Human-in-the-loop automation is positioned to outperform full autonomy in many operations. AI acceleration reduces training time from years to significantly shorter timeframes. The New Warehouse Podcast AI Forklift Platform: Redefining the Operator Experience

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Dude, Where’s My Stuff? Sonaria Answers that Question with RFID

Tue, 05 May 2026 10:05:15 +0000

Welcome to this episode of The New Warehouse Podcast. Kevin chats with John Wirthlin from Sonaria, a solution under the Lowry umbrella, live from MODEX 2026. The conversation centers on shipment verification powered by RFID and how Sonaria is rethinking the operator experience. Instead of leading with technology, the focus is on business outcomes and usability on the floor. Wirthlin walks through how their system simplifies receiving and shipping workflows, reduces costly errors, and delivers real-time visibility without adding complexity. Operator-First Design Changes Adoption Wirthlin makes it clear that most operations are not asking for more technology. As he explains, “we’re all about trying to understand the business outcome first.” Instead of overwhelming users with complex systems, the platform delivers only what operators need in the moment. Many warehouse tools fail because they prioritize features over usability. Wirthlin highlights that “we’re trying to give an experience for the operator that’s operator-centric. And not technology-centric.” That distinction drives adoption. When systems mirror how work actually happens, training becomes almost unnecessary. Operators can move faster without second-guessing the system. This also addresses a common industry gap. Many warehouses still rely on manual checks or fragmented tools. By simplifying the interface and focusing on context, Sonaria reduces friction. The result is faster onboarding, fewer errors, and stronger confidence on the floor. RFID Visibility Solves the “Where’s My Stuff?” Problem One question keeps coming up across industries. As Wirthlin puts it, “A lot of it’s all the same thing. Where’s my stuff?” That challenge spans everything from small electronics to forklifts. Companies want visibility, but they also need accuracy in real environments. RFID has matured, but misconceptions still linger. Some believe it cannot handle metal or complex layouts. Sonaria approaches this differently. Rather than imposing a single solution, they evaluate each environment. Wirthlin explains, “We want to provide the right sensing technology for the right job.” That includes passive RFID, Bluetooth, and ultra-wideband when needed. This flexibility matters because no two warehouses operate the same way. Layout, materials, and workflows all impact performance. By understanding movement patterns and constraints, Sonaria ensures the technology actually delivers value. The outcome is more than tracking. It is actionable visibility. Operators know where items are, how they move, and whether processes are working as expected. Preventing Costly Errors in Real Time Shipment verification is where this approach becomes tangible. The system provides instant feedback as pallets are loaded. There is no delay, no guesswork, and no need for manual scans. The biggest impact comes from error prevention. Wirthlin explains the core goal: “We want to make sure we’re not putting something on the wrong truck.” That single mistake can trigger returns, rework, and customer dissatisfaction. The system also flags more nuanced issues. For example, it prevents refrigerated goods from being loaded onto non-refrigerated trailers. These errors are easy to miss but expensive to fix. Speed is another advantage. As demonstrated, reads happen instantly. This eliminates bottlenecks and keeps workflows moving. Operators get real-time confirmation without slowing down. Key Takeaways on RFID RFID shipment verification provides instant read speeds with no lag during loading System tracks expected vs. actual loads, including pallet counts and case quantities. Prevents mis-shipments by validating the correct truck, product type, and conditions Flags cold chain risks by identifying refrigerated vs. ambient mismatches Supports multiple sensing technologies, including passive RFID, BLE, and UWB The New Warehouse Podcast Dude, Where’s My Stuff? Sonaria Answers that Question with RFID

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Forklift Automation: An Ideal Starting Point for Warehouses

Mon, 04 May 2026 12:54:35 +0000

Welcome to our 700th episode of The New Warehouse Podcast. For this episode, we are going to Yale, forklifts that is. Kevin chats with leaders from Yale Lift Truck Technologies live at MODEX 2026. Featured guests include Brad Long, Kevin McWilliams, and Kyle Smart. They share how Yale is expanding beyond traditional lift trucks into broader warehouse automation solutions. From safer forklift environments to faster deliveries and easier automation starts, the message is clear: modern warehouse automation can be incremental, flexible, and results-driven. Forklift Automation Starts with Solving Real Problems Many automation discussions begin with technology. Yale begins with workflow issues. Brad Long explained, “So we’re really focusing on building a best-in-class warehouse for today and tomorrow.” That framing matters because operators need results now, not only future concepts. He also noted, “We’re thinking about end-to-end, right?” Yale’s focus stretches from warehouse movement to last-mile delivery pain points. Delays in the warehouse often lead to delays at the customer’s door. Long added that at MODEX 2026, Yale is showcasing technologies “that are really changing the face of warehouse and last-mile logistics.” Warehouses increasingly need solutions that connect labor, movement, and final delivery execution. Strong automation strategies solve bottlenecks across the full chain, not in isolated zones. Route Runner Targets Delivery Efficiency Yale’s Route Runner addresses one of retail distribution’s hardest jobs: getting product from truck to shelf quickly. Kevin McWilliams described it simply: “The Yale Route Runner is a nested solution.” The sled fits into the pallet jack, then separates at the store. That allows outdoor movement and tighter indoor maneuvering with one system. He added, “Reduces, touches, reduces step, reduces effort for deliveries.” Those gains matter when routes involve repeated stops and constant handling. Fewer touches can reduce fatigue and improve speed. The ergonomic upside may be even bigger. McWilliams said, “When they don’t have to bend to the floor to lift cases, to put them back in the racks, they can take them off at waist height. It’s been a huge blessing.” The unit also provides 22 inches of lift. In labor-tight markets, equipment that reduces strain can support both retention and productivity. Safer Operations and Easier Forklift Automation Adoption Yale also demonstrated pedestrian awareness technology designed to help forklift operators quickly recognize people. Chad explained that the system helps an operator identify where pedestrians are located and respond accordingly. He also noted it provides alerts “with a visual cue, with an audible cue.” Yale can also trigger truck deceleration through traction alert features. This layered approach supports awareness instead of replacing operator judgment. In robotics, Kyle Smart introduced Yale Relay solutions and a new automated counterbalance stacker. He described a platform that supports “ease of implementation, getting started, with really drag and drop features.” He added, “It’s a great place for customers to get started… earlier in the automation journey.” That message will resonate with operators who want progress without overwhelming complexity. Key Takeaways Yale Lift Truck Technologies is positioning itself as a broader warehouse automation provider, not only a forklift manufacturer. Yale emphasized end-to-end improvement, including warehouse flow and last-mile delivery. Route Runner combines pallet jack and sled functionality for faster store replenishment. The unit offers 22 inches of lift to improve ergonomics and reduce repeated bending. Driver retention was cited as a major customer concern. Pedestrian awareness cameras help operators detect nearby workers through visual and audible alerts. Yale Relay robotics focuses on low-complexity implementation and scalable adoption. The new automated counterbalance stacker targets low-level handling and end-of-line tasks.. The New Warehouse Podcast Forklift Automation: An Ideal Starting Point for Warehouses

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Locus Array: The Next Leap in Warehouse Fulfillment Automation

Thu, 30 Apr 2026 13:17:25 +0000

Welcome to this episode of The New Warehouse Podcast. Kevin chats with Kait Peterson of Locus Robotics live from MODEX 2026. The conversation centers on Locus Array, a new autonomous system built to move beyond pick-assist robotics. Peterson explains how Array was built to answer those demands while working within standard racking and tote environments. This episode offers a close look at where fulfillment automation is heading. Locus Array Expands Beyond Pick Assist Locus built its name around collaborative robots. Array represents a bigger move into full workflow automation. Peterson explains, “Locus Array is a fully autonomous fulfillment robot system.” She adds, “It covers all of the workflows, all the way through the picking process, all the way to packout.” That distinction matters. Many solutions automate only a slice of the operation. Array aims to connect multiple labor-intensive functions into a single robot platform. Peterson also clarified, “The robot also does the put-away function, replenishment, inventory counting, and re-slotting.” The robot stands 10 feet tall and handles six orders at once using different tote sizes. Locus Array can pull inventory from shelves, pick items with an autonomous arm, and deliver completed orders to downstream packing areas. These capabilities are ideal for operators dealing with multiple order profiles. Why Labor Keeps Driving Automation The strongest theme in the interview was labor. Peterson said customer feedback repeatedly pointed to the same issue. “Labor’s such a huge problem in terms of availability, cost, reliability, retention.” She also added a blunt truth many operators understand. “People aren’t picking machines. It’s not a fun job for most people.” That honesty helps explain why demand for warehouse automation continues to rise. Warehouses are not only chasing lower costs. They are also trying to stabilize operations amid turnover, absenteeism, and constant recruiting disruptions. Peterson said Locus designed Array around three customer priorities. “They want storage density maximized. They want to minimize labor and increase their operational capacity 24/7.” Those goals connect directly to executive concerns by delivering more capacity from the same footprint, solutions in unstable labor markets, and better use of overnight hours. Fast Deployment and Smarter Operations Large automation projects often stall because they require major facility changes. Locus is trying to remove that friction. Peterson said, “It’s actually very lightweight. It’s all standard totes and racking.” She added, “So from a customer lift perspective, it’s very, very low.” That message became more concrete with a live example. Peterson noted a newly announced deployment with DHL and said, “Their site was up in four weeks.” Array also uses software intelligence through Locus One. Orders are consolidated before work begins. Picks are clustered by location. Inventory can be re-slotted overnight based on projected demand. Peterson explained, “So in the morning, you come in with totally optimized order profiles.” The robot gets so much attention, but warehouse orchestration delivers the real gains through faster travel paths, better slotting, and less wasted motion. Key Takeaways on Locus Array Locus Array offers full-automation fulfillment. The system combines picking, put-away, replenishment, counting, and re-slotting. Labor shortages, retention, and reliability remain the top drivers of automation. The robot is 10 feet tall and can manage six orders simultaneously. Locus says its network has completed more than seven billion picks. Array was designed to pick 60% to 70% of common customer SKUs initially. Standard totes and racking may reduce implementation complexity. A DHL deployment reportedly went operational in 4 weeks. The New Warehouse Podcast Locus Array: The Next Leap in Warehouse Fulfillment Automation

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Warehouse Automation Trends from MODEX 2026

Mon, 27 Apr 2026 12:50:43 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin chats with Christoph Buchmann of iAutomate and Rueben Scriven of Interact Analysis. Together, they break down what they saw at MODEX 2026 and LogiMAT. The discussion goes beyond show-floor hype and focuses on what warehouse operators actually care about right now. For leaders evaluating automation, this episode offers a grounded look at where the market is heading and what matters most in real operations. Warehouse Automation Trends Are Becoming More Practical At MODEX 2026, there was strong interest in automation, but buyers appeared more selective. Christoph Buchmann said he has been hearing “a bit of a technology fatigue.” He explained that many vendors lead with features while operators stay focused on outcomes. As he put it, “they’re focusing on selling us on their tech versus what really matters from an operational point of view is uptime. How reliable is that system?” That shift matters. Warehouse leaders still want lower cost per pick, space savings, and stronger throughput. However, they are less impressed by novelty alone. Buchmann added that some solutions are becoming over-engineered, which can distract from performance. This creates a healthier market. Buyers are asking harder questions about service levels, ROI, and daily execution. That is a sign the industry is maturing. Instead of chasing the newest concept, operators want dependable solutions that improve the business. AI Is Here, But Real Use Cases Matter AI remained a major topic at MODEX. Still, the conversation is changing. Rueben Scriven noted, “AI’s been on every single stand for the last three, four years.” What stood out this year was the movement toward practical applications. Scriven said, “There are some more functional use cases.” He grouped current warehouse AI into four categories: vision and inspection, execution and optimization, natural language interaction, and physical AI such as humanoids. Among those, vision appears to be gaining the most traction. He explained, “There seems to be a lot of use cases at the show around vision inspection.” That makes sense. Vision tools can improve quality control, detect issues faster, and often leverage existing camera infrastructure. Meanwhile, humanoid robots drew less buzz than expected. Safety and regulation remain barriers. The bigger takeaway is clear: AI excitement alone is no longer enough. Buyers want useful, measurable applications that fit real warehouse workflows. Reliability and Integration Still Decide Deals When operators were surveyed, the top barrier to adoption was not cost. It was complex. Scriven shared, “In fact, it was integration complexity.” That finding says a lot about today’s market. Most warehouses already run layered systems. New automation must connect with WMS, controls, labor processes, and changing order profiles. If that feels risky, decisions slow down. Buchmann echoed that concern, saying, “The integration complexity, I think, is the biggest fear.” Even after evaluating newer technologies, many buyers return to proven options. Buchmann said some companies go back to systems that “just works.” That decision often reflects career risk as much as technical risk. Scriven added another key truth: “Reliability is fundamentally probably the most important factor.” In the end, uptime, support, and confidence often beat flashy demos. For vendors, that means trust may be the strongest differentiator in the market. Key Takeaways Operators are prioritizing uptime, reliability, and ROI over flashy features. Technology fatigue is emerging as similar solutions flood the market. AI is evolving from branding language into practical use cases. Vision inspection technologies ranked high in terms of future investment interest. Interact Analysis surveyed about 400 operators for recent findings. Integration complexity was the number one barrier to automation adoption. Scalability matters more because future demand remains uncertain. Proven systems often win because they lower operational and career risk. Humanoid robots generated less buzz than many expected at MODEX 2026. The New Warehouse Podcast Warehouse Automation Trends from MODEX 2026

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Parcel Shipping Operations: Moving Packages in Minutes with DHL

Thu, 23 Apr 2026 14:42:01 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Eric Ricardo, VP of Operations at DHL eCommerce. Eric breaks down how DHL eCommerce operates within the broader DHL network and how it connects retailers to end consumers. The conversation centers on parcel throughput optimization, network design, and the balance between automation and labor. Eric shares how DHL moves millions of packages daily, manages peak demand fluctuations, and plans years in advance to maintain speed and consistency. More importantly, he explains how throughput defines success in modern parcel shipping operations. Designing Facilities for Speed and Throughput DHL eCommerce is built around one core idea: move packages as fast as possible. Unlike traditional warehouse models, storage is not the goal. Instead, every design element maximizes flow through the building. Eric highlights the scale of parcel shipping operations, noting “we move millions of packages per day.” That volume requires facilities engineered for speed. Some sites can handle extreme throughput, with Eric explaining, “Our largest facility can process up to 70,000 packages an hour.” These aren’t static environments but instead systems designed to handle fluctuating demand, especially early in the week when volume spikes. This focus drives how facilities are built and measured. Eric emphasizes that success comes down to “Throughput per square foot.” That metric forces teams to maximize output from every inch of space. Instead of large storage footprints, DHL prioritizes compact, high-velocity sortation environments. Why Throughput Is Measured in Minutes, Not Days Parcel shipping operations function on a completely different time scale than traditional warehousing. DHL doesn’t think in days or weeks. It thinks in minutes. Eric explains the difference clearly: “We want to get it in, we want to get it out as quickly as possible. We don’t store things.” That mindset shifts everything from layout to labor strategy. Instead of inventory dwell time, DHL measures performance in near real-time flow. The goal is aggressive. Eric shares, “The challenge that I’ve given our industrial engineers… is to have nothing sitting in a facility for more than an hour.” That target pushes continuous improvement across automation, staffing, and process design. To make that possible, parcel shipping operations must feel fast, almost chaotic. But there’s structure behind what others would perceive as chaos. As Eric describes it, “it’s an orchestrated symphony with all these.” Every system, person, and process must stay aligned to maintain that flow. Balancing Automation, Labor, and Future Growth Automation plays a major role, but it is not the entire story. DHL approaches technology with a practical mindset, focusing on ROI and scalability rather than chasing trends. Eric points to new models like flexible deployment, saying “robot as a service has popped up and made a difference over the last five or six or seven years.” This allows DHL to test solutions without heavy upfront investment. It also creates room to adapt as technology evolves. Still, people remain critical. Eric makes it clear that automation does not eliminate the workforce. Instead, roles evolve. As he puts it, “you’re only gonna be as good as the people that are bolting on and working with that automation.” Even as systems improve, human oversight, planning, and maintenance remain essential. Looking ahead, DHL continues to invest in both technology and talent. With long-term projects and ongoing pilots, the company is positioning itself to scale alongside e-commerce growth while maintaining reliability and consistency. Key Takeaways on Parcel Shipping Operations DHL eCommerce moves millions of packages daily across a network of nearly two dozen U.S. facilities Peak volume can double early in the week compared to later days Largest facilities can process up to 70,000 packages per hour Throughput per square foot is a primary KPI for facility performance Parcel dwell time is measured in minutes, not days or weeks The target goal is under one hour of dwell time per package in a facility DHL invested roughly $300 million in network upgrades over a multi-year period DHL designs facilities to scale and adapt to future automation Robot-as-a-service models enable flexible testing of new technologies Labor remains essential, with roles shifting toward higher-skill functions Reliability and consistency are key differentiators for customers Customer expectations are shifting toward balancing speed and cost

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Being a Food Whisperer: How Lineage Applies Inside the Box Thinking in Food Logistics

Mon, 20 Apr 2026 15:25:20 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Dr. Stephen Neel of Lineage about what it really takes to manage food safely at scale. Lineage operates one of the world’s largest temperature-controlled warehouse networks, but this conversation makes it clear they see themselves as much more than cold storage. Dr. Neel walks through how food behaves differently from other products, why microclimates matter, and how traceability is reshaping operations. More importantly, he introduces a mindset shift that challenges how most warehouses think about efficiency, risk, and responsibility. Rethinking the Role of Cold Storage in Food Logistics At its core, Lineage simplifies its business, reframing everything else. As Neel explains, “We sell cold air. We have one commodity. It’s cold air. You can buy it in three flavors, you know, cool, cold, and very cold.” Each flavor has a deeper responsibility for food safety and product integrity. The job is not just storage. It is protection. Neel reinforces this clearly, noting, “Fundamentally, our job is to keep food cold, keep it covered, keep it moving.” That means every movement introduces potential risk. Lineage embeds itself into the customer’s operation. As he puts it, “We become an extension of their business.” This shifts the warehouse from a passive node to an active partner responsible for outcomes, not just throughput. Inside the Box Thinking Changes Everything Traditional warehouses focus on pallets, locations, and flow. Dr. Neel focuses on what is inside each case. That shift is where “inside the box thinking” comes to life. He explains that risk increases during transitions, stating, “When we’re changing phases… it actually allows us to introduce risk.” Whether it is receiving, storing, or value-added services, each step must be evaluated from the product’s perspective. That perspective is highly specific. As Neel describes it, “We have to understand what’s inside the box so that we can anticipate that microclimate impact.” This includes temperature sensitivity, airflow, and handling conditions. He even frames it conceptually. Dr. Neel says, “If you sort of think of yourself as a food whisperer, you have to put yourself in the place of that commodity.” That mindset drives decisions that go beyond standard warehouse logic. Data, Traceability, and the Future of Food Logistics As operations grow more complex, data becomes essential. Dr. Neel does not treat data as a support function. It is central to execution. As he puts it, “It’s a very data-driven business.” That data must move with the product. The warehouse is no longer just a place to store goods. It is managing information. Dr. Neel highlights this shift, saying, “The warehouse is expected to capture, store, and communicate all that information through in an accurate and seamless manner.” Traceability is the next major challenge. It is not optional, and it is not easy. Neel explains, “When we talk about traceability, it’s about real-time data capture.” However, execution is difficult. As he notes, “In theory, that makes great sense. In application, it’s a systems nightmare.” Looking ahead, expectations will only increase. The industry must respond faster and more efficiently. As Dr. Neel states, “We’re gonna have to give it to them faster, better, and cheaper.” Key Takeaways Lineage operates with a simple model but carries complex food safety responsibilities. Food logistics requires product-level thinking, not just pallet-level efficiency. Microclimates and product sensitivity directly impact handling decisions Every operational transition introduces risk, especially during value-added services Warehouses are becoming data hubs, not just storage facilities Real-time traceability is essential but difficult to implement at scale Food safety is non-negotiable across every touchpoint Future expectations demand faster, more accurate, and cost-effective operations The New Warehouse Podcast Being a Food Whisperer: How Lineage Applies Inside the Box Thinking in Food Logistics

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Logistics Hub Development: How Franklin County Became a Powerhouse

Wed, 15 Apr 2026 15:38:44 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Mike Ross, President of the Franklin County Area Development Corporation (FCADC). Ross has spent over 40 years in economic development and walks through how Franklin County, Pennsylvania, became a true logistics hub. They get into what actually drives that kind of growth. It’s not just location. It’s infrastructure, long-term planning, and knowing how to land the right projects at the right time. The Foundation of a Logistics Hub Franklin County sits along Interstate 81, one of the most important freight corridors in the country. That matters more than anything else. As Ross explains, “When you want to understand how you become a logistics hub, have one of the premier interstates in the country come through your county.” Access alone doesn’t build a logistics hub. Early on, the county had to make real investments. One example was redesigning an interchange to support Food Lion’s distribution center. That project opened the door for everything that followed. And none of it happens quickly. Ross puts it simply: “The building construction’s the easiest part of it.” The real work is everything leading up to that. Permits. Traffic studies. Funding. Years—sometimes decades—before a shovel hits the ground. Momentum Builds Through Strategic Projects Once the first major projects land, things start to shift. Franklin County saw that with Food Lion, Ingram Book, and Target. Those weren’t just wins—they were signals to the rest of the market. Ross captures that moment well: “If they’re going there, what are they seeing that we should be looking at?” That’s how momentum builds. Other companies start paying attention. Developers follow. At the same time, the scale has changed. What used to be a large facility doesn’t even register the same way now. As Ross explains, “Anything under a million square feet now is considered more of a smaller project.” That shift says a lot about where demand is heading. Bigger footprints. Faster throughput. Closer to the customer. Balancing the Economic and Community of a Logistics Hub Growth brings pressure: more buildings, more traffic, more scrutiny from the community. Franklin County has tried to stay ahead of that by keeping development close to interchanges and away from residential areas. That approach has paid off. The region has supported over 1,070 projects, driving $3.7 billion in investment and impacting 62,000 jobs. And the jobs themselves have changed, but it’s no longer low-wage warehouse work. These roles compete with manufacturing and healthcare. The benefits are better. Expectations are higher. Location still does a lot of the heavy lifting, though. As Ross puts it, “We are within a 24-hour drive of 50% of the North American population.” That kind of reach is hard to beat—and it’s why the region keeps attracting investment. Key Takeaways on Logistics Hub Development Franklin County leveraged Interstate 81 to become a logistics hub serving 50% of North America within 24 hours. FCADC supported 1,070 projects, generating $3.7 billion in investment and impacting 62,000 jobs Early anchor projects such as Food Lion and Target created a ripple effect that attracted additional companies. Warehouse sizes have scaled from 500,000 sq ft to 1M+ sq ft as the new standard. Infrastructure development can take decades, even though buildings go up quickly. Strategic zoning keeps warehouses near interchanges while preserving farmland. The New Warehouse Podcast Logistics Hub Development: How Franklin County Became a Powerhouse

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3PL Fit: Staying in Your Lane Drives 3PL Growth

Mon, 13 Apr 2026 15:45:43 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Dave Harriger, CEO and Founder of Swifthouse, about the evolution of his 3PL business and the journey to implementing a new WMS. Based just outside Philadelphia, Swifthouse supports e-commerce brands with fulfillment services from pick and pack to shipping and tracking. Dave shares how early growth, major client shifts, and operational challenges forced him to rethink his strategy. The conversation explores why defining your niche, building strong processes, and saying no to the wrong clients can ultimately drive better, more sustainable growth. Finding the Right 3PL Fit Swifthouse didn’t start as a traditional 3PL. Dave built the foundation through a textbook resale business that scaled nationwide. That experience created operational discipline, but the transition to serving clients introduced new challenges. Early on, Swifthouse landed a major Amazon reseller. The volume was strong, but the risk was hidden. As Dave explains, “they could give us as much inventory as we could handle, and overnight they could change their strategy.” That risk became reality when the client reduced its warehouse network from 14 to three. The result was excess capacity and a forced reset. Instead of downsizing, Dave kept his team intact and used the moment to refocus. He jokes, “We probably had the best swept warehouse in the country as we navigated through that.” That led to a critical realization on 3PL fit: “empty racks are better than a bad fit.” Dave shares the dilemma many 3PLs face, trying to be everything to everyone. Once Swifthouse figured out who they work better with and that they aren’t a great fit for everyone, things started to click. And now, he’s gotten comfortable with saying “no.” From there, the company shifted toward serving smaller brands where relationships, flexibility, and alignment mattered more than sheer volume. Process First, Then Technology As Swifthouse grew, its original systems began to break down. The team relied on adapted software from the textbook business, but scaling exposed its limits. Dave highlights a key lesson many operators overlook: “what works isn’t the same as what scales.” Transitioning to a true WMS became necessary, but the first attempt failed due to insufficient preparation. The turning point came when they focused inward. Much of their operation relied on undocumented knowledge. As Dave puts it, “the stuff that’s living in people’s heads can’t get into a WMS because it’s in their heads.” That insight drove a six-month effort to standardize processes, billing, and workflows before selecting new technology. It started by identifying who Swifthouse is and who they serve best. This shift reframed the entire approach. Instead of expecting software to fix problems, Swifthouse built a foundation that technology could actually support. When it comes to selecting a WMS, Dave advises, “Do it sooner than you want it. It gets harder the longer you wait. Especially for a startup 3PL.” Scaling with Discipline and Clarity With a clearer strategy and stronger processes, Swifthouse began to scale more intentionally. That included redefining who they serve and how they operate. At the same time, the business doubled down on its positioning. “We’re boutique on purpose,” Dave says, reinforcing their commitment to high-touch service and direct communication. This approach shows up in daily operations. For example, the team proactively identified packaging changes that reduced shipping costs for a client by getting orders under one pound. Dave explains they differentiate themselves by designing processes that eliminate the back-and-forth and by providing simple billing. “ The goal is to take fulfillment off a brand’s plate without them needing an accounting degree to make sure it’s done correctly.” These types of insights come from experienced staff and close relationships—advantages that larger providers often struggle to replicate. Key Takeaways on 3PL Fit Swifthouse scaled from a textbook resale business into a full 3PL operation starting in 2020 The company chose to maintain its team during low volume instead of cutting headcount. Boutique positioning allows Swifthouse to focus on small and mid-sized brands, not enterprise clients. Standardizing billing and workflows was a key step before implementing software. Scan-based picking improved accuracy and enabled broader team participation. SKU mapping allows both clients and operators to use different naming conventions seamlessly The New Warehouse Podcast 3PL Fit: Staying in Your Lane Drives 3PL Growth

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Mixed Case Palletizing: Jacobi Robotics and the Holy Grail

Wed, 08 Apr 2026 13:14:29 +0000

Kevin chats with Max Cao, Co-founder and CEO of Jacobi Robotics, and Pete Allen, who wears many hats, including serving as a Board Adviser for Jacobi. Together, they discuss long-standing challenges of tackling mixed-case palletizing in warehouse operations. Jacobi Robotics enables robots to handle complex, real-world case flows without requiring massive infrastructure changes. The conversation explores how Jacobi is bridging the gap between research and real deployment, why brownfield environments matter, and how their Omni Palletizer is making automation more accessible across industries. Why Mixed Case Palletizing Has Been So Difficult Mixed case palletizing has challenged the industry for decades. Many solutions rely on heavy infrastructure and perfect sequencing upstream. That approach works in controlled environments, but not in most warehouses. As Max explains, “We observed that the gap between what was possible in a research setting and what was commercially deployed in a warehouse is quite enormous.” Instead of imposing ideal conditions, Jacobi examined real operations. Warehouses deal with randomness every day. Pete highlights this shift clearly, noting “when boxes are coming down the line, when you haven’t sequenced them upstream, you’ll see a variety of case flows.” This includes imperfect, random, and highly variable flows. That complexity is why the problem remained unsolved. Traditional systems require sequencing, large footprints, and major investment. Most operators simply cannot justify it. Jacobi’s approach flips that model. They built software that adapts to the chaos instead of eliminating it. Max shares how Jacobi tackles this challenge. “We’re not asking the warehouse to behave like a lab. The lab has to fit around the warehouse.” Bringing AI Into Real Warehouse Operations Rooted in physical AI, Jacobi’s solution predicts actions. It learns how to place cases in real time based on experience. As Max puts it, “physical AI will try to predict the next sort of physical action.” They train the system using millions of real-world data points. That includes case dimensions, weights, and actual order flows. Over time, it builds a general stacking model that continues to improve. Max explains the impact simply: “It gets better over time just as a person would.” This learning capability allows the system to handle unpredictable environments. It can adapt to new SKUs, changing demand patterns, and different customer profiles. Instead of rigid programming, the system evolves. For years, this challenge has been out of reach, as “it’s been called the holy Grail of warehouse automation.” Making Automation Work in Brownfield Environments Most warehouses are complex, constrained, and constantly running. That reality shaped Jacobi’s entire strategy. As Max explains, “Brownfield is the majority of the market.” Max explains the brownfield constraint on automation projects, stating, “You cannot shut down these operations for six to 18 months.” Jacobi addresses this by designing modular robotic cells and simulations. The team builds a digital twin using real customer data to predict performance. The result is a robot that behaves more like an experienced operator, fully capable of building dense, stable pallets even when the input data is inconsistent. And that’s where the real breakthrough shows up in practice. As Pete Allen explains, “if you could have a low-cost solution with a great ROI that could be just put into a Brownfield… boy, you got something.” Key Takeaways on Mixed Case Paletizing Mixed case palletizing has been considered the “holy grail” of warehouse automation for over 20 years. Traditional solutions rely on sequencing and large ASRS systems, limiting adoption. Jacobi’s approach handles imperfect and fully random case flows in real operations. The system is trained on millions of real-world data points from warehouse environments. AI continuously improves performance through learning and adaptation. Brownfield warehouses represent the majority of automation opportunities. Deployment timelines have been reduced from months to just a few weeks. The New Warehouse Podcast Mixed Case Palletizing: Jacobi Robotics and the Holy Grail

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IC to Electric: 90% Fuel Savings, Lower Maintenance, and Smarter Forklift Decisions

Tue, 07 Apr 2026 15:22:33 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Martin Boyd of Big Joe Forklifts about one of the most important shifts happening in material handling today. Big Joe has built its reputation on simple, cost-effective electric equipment and is now pushing deeper into lithium-powered solutions. The conversation centers on what it really takes to transition from internal-combustion to electric forklifts. More importantly, it explores why many operations hesitate, what has changed in technology, and how companies can make the transition without overspending or sacrificing performance. Why the Shift from IC to Electric Is Happening Now The move toward electrification isn’t new, but the conditions finally make it practical. For years, operations stuck with propane or diesel because electric options lacked power or flexibility. That’s no longer the case. As Boyd explains, “the technology has really reached a point where moving from IC to electric makes sense.” Lithium-ion batteries have changed the equation. “The cost of lithium has calmed down, and it’s allowed operations using internal combustion to completely leapfrog over older technology and go right into lithium-based technology.” This move delivers consistent power, faster charging, and longer runtime. Cost is also driving the shift. Fuel and maintenance continue to eat into margins. Boyd points out that “you’re looking at probably a 90% reduction in fuel savings going from propane to electric.” That kind of reduction forces leaders to take a closer look. Add in a 40–60% drop in maintenance, and the financial case becomes difficult to ignore. What Still Gets in the Way of Electrification Even with better technology, many operations hesitate. The biggest barrier isn’t performance. It’s understanding. Boyd is clear on this point: “One of the challenges we see is just awareness.” Many teams still view electric as underpowered or risky. There’s also a lingering fear tied to uptime. As he puts it, “there’s always this fear that the forklift is gonna run out of juice.” That perception slows decision-making, even when the data says otherwise. Another issue is how solutions are sold. Electrification isn’t just swapping equipment. It requires a different conversation around energy use, charging behavior, and fleet sizing. Boyd notes that “Moving to electric is a completely different discussion.” Without the right guidance, buyers default to oversizing batteries and chargers, which unnecessarily drives up costs. This creates friction. Operators either delay the transition or invest more than necessary. In both cases, the value of electrification gets lost. How Data-Driven Decisions Change the Equation The most effective transitions start with data. Understanding how trucks are used day to day allows operators to right-size their electric fleet. Boyd emphasizes a practical approach: “We will use data to show you that it’s possible.” Instead of guessing, teams can analyze duty cycles, charging windows, and energy consumption. This eliminates the need to overbuild the solution. That’s where many operations go wrong. Boyd warns, “When you oversize the battery and you oversize the charger, you pay a lot of money.” The goal isn’t to buy the biggest system. It’s to find the right one. Lithium technology also supports this shift. Frequent, fast charging becomes an advantage rather than a limitation. As Boyd explains, “Lithium loves to be charged. It loves to be charged fast; it loves to be charged often.” That flexibility allows operations to maintain uptime without excess capacity. In the end, data turns uncertainty into confidence. It changes the conversation from risk to optimization. Key Takeaways Lithium-ion enables a practical shift from IC to electric forklifts Up to 90% reduction in fuel costs when switching from propane 40–60% reduction in maintenance costs with electric fleets Electrification requires a different buying and operational mindset Awareness and education remain the biggest adoption barriers Fear of downtime still slows decision-making despite improved performance Oversizing batteries and chargers is a common and costly mistake Data-driven analysis helps right-size fleets and reduce upfront spend The New Warehouse Podcast IC to Electric: 90% Fuel Savings, Lower Maintenance, and Smarter Forklift Decisions

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Right-Sized Packaging: A Box Last Approach Means Lower Costs & Less Waste

Tue, 07 Apr 2026 15:11:44 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Jeff Belcher, General Manager at CMC Packaging Automation, and Craig Hall, Head of Sales for North America. Together, they explore how right-sized packaging automation is reshaping fulfillment operations. CMC, a family-run company with over 40 years of history, has evolved from mailing and wrapping to become a leader in automated e-commerce packaging. The conversation focuses on the shift from manual pack stations to machine-level packaging, the rise of right-sized solutions, and how operators can rethink packout to improve efficiency, reduce waste, and better handle the complexity of modern orders. From One-Size Boxes to Dynamic Packaging E-commerce has changed what packaging needs to do. Orders are no longer predictable, and operations must adapt in real time. As Craig explains, “it’s no longer one size fits all.” This shift has pushed companies toward systems that can create packaging on demand rather than relying on pre-set box sizes. Right-sized packaging automation addresses this by building the box around the product at the moment of packout. Instead of selecting from a limited set of boxes, the system determines dimensions via a cube scan and produces an exact fit. That reduces void fill and improves cube utilization across shipments. Craig reinforces the core principle behind this approach, noting “every box that you’re going to make, or every bag that you are potentially making needs to be a different size.” The result is fewer shipments, better truck utilization, and lower environmental impact. Moving Packaging to the Machine Level Traditional pack stations rely heavily on labor. Workers select boxes, pack items, and manually apply labels. Right-sized packaging flips that model by pushing those decisions and actions into the machine itself. CMC’s “box last” approach removes dependency on upstream data accuracy. Instead of relying on item master data, the system captures dimensions in real time and builds the packaging accordingly. As Jeff explains, “everything is being done at the machine level,” which simplifies integration and reduces complexity. This shift also changes how labor is used. Rather than focusing on repetitive packing tasks, teams can be reassigned to higher-value activities. The packaging machines handle sizing, cutting, labeling, and sealing in one continuous flow. However, automation introduces a new operational reality. Speed is only valuable when you can feed the system consistently. Craig highlights this clearly: “The question is, can I pick it that quickly and can I feed it that quickly?” That balance between upstream flow and downstream automation becomes critical. Designing for Real-World Operations Implementing right-sized packaging is not just about installing a machine. It requires rethinking flow, space, and throughput across the operation. Many facilities transition gradually, keeping some manual pack stations for overflow and peak demand. The biggest driver behind adoption is labor. Peak seasons require large temporary workforces, and competition for labor is intense. Automation helps stabilize operations and reduce reliance on seasonal hiring. CMC’s approach also emphasizes flexibility. Their systems can be configured based on customer needs rather than forcing a standard setup. Craig points out that customization is often the deciding factor, saying “it’s what happens after the, but that I would say is where CMC probably differentiates itself.” At the same time, there are common misconceptions. Some operators assume complex integrations or restrictive consumable models. In reality, the systems are designed to integrate simply and allow customers flexibility in sourcing materials. As Jeff puts it, “it’s a dumb machine. It will do what you tell it to do.” Key Takeaways on Right-Sized Packaging Right-sized packaging automation enables dynamic box creation based on real-time dimensions rather than fixed sizes. E-commerce growth and multi-item orders are driving the need for more flexible packaging solutions. Systems can run at speeds of up to 3,000 packages per hour, requiring consistent upstream feeding. Cube scanning removes reliance on inaccurate item master data and improves packaging accuracy. Machine-level packaging reduces labor dependency and reallocates workers to higher-value tasks. The New Warehouse Podcast Right-Sized Packaging: A Box Last Approach Means Lower Costs & Less Waste

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Warehouse Real Estate Market Finding Balance

Wed, 01 Apr 2026 20:05:00 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Brandon Page, Executive Vice President and Head of Leasing and Customer Solutions at Link Logistics, and Stephanie Rodriguez, National Director of Industrial Services at Colliers. Together, they break down how the warehouse real estate market is shifting into a more balanced state. Link Logistics, with roughly 3,000 buildings and 470 million square feet, represents a massive footprint across the U.S., while Colliers brings a global advisory perspective. The conversation explores changing demand patterns, evolving decision-making, and what warehouse operators need to understand as they evaluate space in today’s market. The Warehouse Real Estate Market Shift Once defined by extreme demand or oversupply, the warehouse real estate market is settling into a more stable and competitive environment. As Brandon explains, “the first word that comes to mind, I think, is balanced.” Vacancy rates now average around 7–8% nationally, giving tenants more options while still maintaining activity for landlords. However, balance doesn’t mean ease. Brandon notes that “it doesn’t feel great, which suggests that it’s certainly not as landlord-friendly as it was during COVID.” This shift reflects a broader normalization after years of unprecedented demand. Tenants now have leverage, and landlords must compete more aggressively on pricing and concessions. At the same time, demand has not disappeared. Instead, it has slowed in execution. Larger deals, especially those above 250,000 square feet, have lagged, while smaller, last-mile spaces remain active. This “tale of two markets” highlights how operators are adjusting strategies rather than stepping away entirely. Why Demand Paused, Not Disappeared Uncertainty is largely to blame for the slowdown in large-scale leasing. Stephanie points out that “there was such tremendous activity in industrial real estate 2020 into, you know, 2023,” followed by a surge in construction that flooded the market with new space. As that supply hit, demand stabilized. Tenants became more cautious, especially when committing to large footprints. Stephanie explains, “Tenants didn’t wanna make those big bets.” Instead of locking into long-term, high-cost leases, many operators chose smaller spaces or delayed decisions altogether. Companies are taking longer to evaluate risk, often involving more stakeholders. With C-suite leaders now heavily involved, decision timelines have stretched. This added scrutiny has slowed deals, even as operational needs continue to grow. The result is a market where activity exists, but execution requires more effort, more data, and more confidence than before. The New Decision Drivers for the Warehouse Real Estate Market While location has always been critical, the factors driving site selection are evolving. Stephanie highlights that “power availability is huge.” As automation, robotics, and AI adoption increase, power infrastructure has become a top priority for tenants planning long-term operations. Labor competition is intensifying across the warehouse real estate market, especially in dense industrial hubs where facilities cluster together. As Stephanie Rodriguez explains, “the labor market is very competitive, especially in some of these locations where we see, bulk building after bulk building, they are all fighting for the same workers.” To stand out, many operators are investing in on-site amenities and more engaging work environments to retain and attract talent. Location continues to play a dominant role, especially for last-mile operations. As Brandon puts it, “the old location, location, location still rings through.” Proximity to customers can outweigh even the most advanced building features. “The Sunbelt is definitely an area that’s seeing tremendous growth with tremendous demand.” That momentum is being reinforced by nearshoring & reshoring, population growth, rising consumption, and the broader economic tailwinds shaping markets like Dallas, Atlanta, and Phoenix. Key Takeaways The industrial market is stabilizing with vacancy rates around 7–8%. Large leases (250,000+ sq ft) slowed, while smaller spaces remain active. Post-pandemic construction created a temporary oversupply of space. Power availability is now a top site selection factor for tenants. Roughly 70% of demand in 2025 targeted modern big-box facilities. Link Logistics operates ~3,000 buildings and 470 million sq ft. Nearly 5% of U.S. GDP moves through Link’s facilities. 3PLs are re-entering the market as excess “shadow space” declines. The New Warehouse Podcast Warehouse Real Estate Market Finding Balance

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Modular Warehouse Solutions That Adapt to Change

Mon, 30 Mar 2026 13:05:51 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Ben Hull, Director of Sales at Item America, about how modular warehouse solutions are reshaping operations. Item America, a German-based company with a growing U.S. presence, specializes in aluminum extrusion systems that allow teams to design and build custom solutions on the shop floor. From ergonomic workstations to AMR-compatible carts, the conversation explores how flexibility, customization, and continuous improvement are driving smarter warehouse design. Hull shares how modular thinking helps operations reduce waste, adapt faster, and create solutions that truly fit their needs. From Industrial Legos to Custom Modular Warehouse Solutions At its core, Item’s approach is simple but powerful. As Hull explains, “you know, a rector set, or we like to call it industrial Legos.” That comparison captures the essence of modular warehouse solutions—standardized components that unlock endless customization. Instead of relying on fixed equipment, operations can design around their exact needs. Hull emphasizes that every solution begins with an idea. “Really, it starts with an idea. It starts with a thought. And then we just allow somebody to have the different products available to then create that idea into reality.” This mindset shifts how teams think about equipment. Rather than adapting processes to fit tools, they build tools to fit processes. Over time, this approach supports continuous improvement by eliminating unnecessary steps and simplifying assembly, replacing traditional welding and fabrication with faster, more flexible builds. item Building Kit System – THE profile technology for modular, industrial applications Why Flexibility Matters on the Floor Warehouse environments are constantly evolving. Labor challenges, product variability, and operational shifts demand adaptable solutions. Hull points out that traditional setups often create inefficiencies. “Everything will find its way onto that cart.” That clutter leads to wasted motion and disorganization. Modular warehouse solutions address this by creating purpose-built designs. “Everything has its place. It keeps for a very clean, lean environment.” Instead of generic carts or workstations, teams can design around specific workflows, improving efficiency and reducing waste. Just as important, these systems evolve with the operation. When needs change, teams can adjust rather than replace entire setups. That ability to modify rather than scrap equipment supports long-term cost savings and operational agility, especially in fast-changing environments like e-commerce and manufacturing. How Modular Warehouse Solutions Support Automation and Ergonomics As automation grows, modular design plays an even bigger role. AMRs require customized top modules to handle different product sizes and weights. Hull highlights the advantage of lightweight aluminum structures. “You’ve aided the ability to then put more weight on that structure, so you can move more product that way.” This directly improves throughput and efficiency. There’s also a hidden benefit tied to energy usage. “Your runtime and your battery length extend on those AMRs.” Lighter structures reduce strain on robots, increasing uptime. Beyond automation, modular systems improve ergonomics. Adjustable workstations and tools positioned within a “golden reach” zone reduce strain and repetitive motion. These small design improvements add up, boosting productivity while supporting employee safety and comfort across shifts. One standout example comes from Area Two Farms, where a full-scale indoor growing structure, roughly 20 feet in each direction, was built entirely using the system, showing just how far modular design can go. Key Takeaways Modular systems allow warehouses to build solutions around processes, not the other way around Custom carts and workstations reduce clutter and improve operational efficiency Lightweight aluminum structures increase AMR payload capacity and runtime Modular designs eliminate welding and reduce the time required for assembly and changes Ergonomic improvements, like adjustable stations and reach optimization, reduce worker strain Operations can modify existing setups instead of replacing them, lowering long-term costs Growing adoption in the U.S. reflects a shift toward flexible, right-fit solutions over off-the-shelf equipment The New Warehouse Podcast Modular Warehouse Solutions That Adapt to Change

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On-Demand Warehousing Solves Distressed Freight Problems

Wed, 25 Mar 2026 12:54:44 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Dave Gutierrez, Vice President of Sales at OLIMP Warehousing. OLIMP operates a digital marketplace that connects available warehouse capacity with companies that need fast logistics support. The conversation explores the growing demand for on-demand warehousing and why it is becoming an essential tool for brokers, carriers, and warehouse operators. Gutierrez explains how OLIMP helps solve urgent freight problems, particularly when shipments are rejected, damaged, or delayed. By connecting warehouses with immediate service opportunities, OLIMP enables businesses to recover disrupted shipments while helping warehouses monetize unused labor and space. How On-Demand Warehousing Connects Capacity and Urgent Needs On-demand warehousing helps companies solve urgent logistics problems by connecting freight that needs immediate attention with available warehousing and storage. Gutierrez explains that OLIMP’s model is designed specifically for these time-sensitive situations. As he puts it, “OLIMP is a digital marketplace to connect available warehouse capacity with people who need it on-demand warehouse services.” Many of OLIMP’s customers are brokers and carriers facing real-time delivery disruptions. For example, a shipment may arrive at a retailer with damaged pallets or improperly wrapped freight. Instead of returning the freight to the shipper, the carrier can quickly find a nearby warehouse to rework the load. Gutierrez notes that “most of our customer base, probably 90%, is in the brokerage and carrier space where they’re looking for same-day on-demand services.” The platform acts as a service marketplace, routing requests through an RFQ system and matching them with available warehouses in minutes. While automation plays a role, relationships remain critical. OLIMP staff still communicate directly with warehouse partners to confirm availability and ensure the work can be completed quickly. Distressed Freight Is Driving the Market One of the biggest drivers behind on-demand warehousing is what Gutierrez calls “distressed freight.” These situations occur when freight cannot continue moving through the supply chain as planned. Gutierrez explains, “We call that distressed freight.” Distressed freight can occur for many reasons. A truck may miss a delivery appointment, a load may shift during transit, or a receiver may reject freight because pallets are damaged. In these situations, drivers often become stuck waiting for instructions while carriers absorb additional costs. Gutierrez highlights how common these situations are, noting that “that portion of our business makes up, in terms of order volume, a substantial portion, probably close to 70% of the orders that we see.” The impact extends beyond a single shipment. When a truck cannot unload, the trailer remains occupied, and the driver cannot move to the next job. By quickly transferring freight to a warehouse for restacking, storage, or inspection, companies can keep trucks moving while resolving the issue more efficiently. Turning Idle Warehouse Capacity Into Revenue For warehouse operators, on-demand warehousing offers a way to turn unused space and labor into incremental revenue. Many facilities experience occasional utilization gaps, whether due to seasonal demand shifts or fluctuating freight volumes. Gutierrez describes the opportunity from the warehouse perspective: “I’m sitting here with some empty racks, and more importantly, I’ve got a couple of guys standing around holding up brooms today instead of doing any work.” Rather than searching for small, short-term jobs through traditional sales channels, warehouses can use OLIMP’s platform to bid on work posted in their area. Gutierrez explains the financial logic simply: “If I could make four or 500 bucks, restacking a couple loads for carriers, handling a couple extra trucks today, that makes a ton of sense for me.” These quick-turn projects can include restacks, cross-docking, short-term storage, transloading, and inspection holds. Over time, some short-term jobs even evolve into longer-term storage projects, creating new business opportunities for warehouse partners. Key Takeaways Distressed freight drives a significant portion of on-demand warehousing demand, representing roughly 70% of OLIMP’s order volume. OLIMP primarily serves brokers and carriers, with about 90% of customers coming from the brokerage and carrier space. On-demand warehousing can resolve urgent logistics disruptions such as missed appointments, rejected freight, damaged pallets, and insurance inspections. The platform connects freight needs with available capacity using a digital RFQ portal and warehouse job board system. Many requests are extremely time-sensitive, with warehouses sometimes receiving trucks within an hour of the request. Warehouse operators can monetize unused labor and space by accepting short-term restacks, cross-dock jobs, and overflow storage projects. On-demand warehousing helps reduce costly delays by quickly moving freight off trucks and into nearby warehouses. The model benefits both sides of the market by simplifying relationships and eliminating the need for multiple individual warehouse accounts or contracts. The New Warehouse Podcast On-Demand Warehousing Solves Distressed Freight Problems

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Finding a Home for Excess 3PL Inventory

Tue, 24 Mar 2026 12:31:10 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Abby Nawrocki, CEO and Founder of Stock. Abby brings deep experience in operations and logistics, having worked with companies like DHL, Radial, Shopify, and Flexport. Her company, Stock, focuses on solving a growing supply chain problem: excess 3PL inventory. Through a marketplace model, Stock connects warehouses and brands with nonprofit organizations that can use surplus goods. The conversation explores how excess 3PL inventory builds up, why traditional liquidation often fails, and how alternative channels, such as donation, can create both financial and social value for modern warehouse operators. Excess 3PL Inventory Is a Growing Supply Chain Challenge Excess 3PL inventory has long existed in retail and distribution networks, but its scale has grown dramatically in recent years. Abby’s experience managing Zara’s U.S. distribution operations exposed her early to the challenge of unsold product. Even major retailers struggle to recover value from surplus goods. Abby explains that “when it comes to liquidation, less than 20%, almost 5% of what retailers or brands present to liquidation actually gets sold.” The problem has become even more pronounced in the direct-to-consumer economy. During Abby’s time working with Shopify-focused logistics networks, she saw how quickly brands could rise—and disappear. Warehouses serving these brands frequently inherit unsold product after companies shut down. As Abby notes, “There are 4 million brands that sell on Shopify, but 90% of them go out of business in the first three years.” That failure rate leaves 3PLs dealing with abandoned pallets and excess inventory that often has no clear path forward. Why Traditional Liquidation Often Falls Short For many warehouses, liquidation has long been the default strategy for moving excess 3PL inventory. In practice, however, the process can be slow and inefficient. Inventory may sit in storage for weeks while buyers are sourcing and negotiating. Abby points out that “in traditional liquidation, it takes 16 weeks on average to go from calling a liquidator to actually leaving the warehouse physically.” During those months, valuable warehouse space remains tied up with non-moving goods. Abby notes that the cost of idle pallets extends beyond storage fees and can affect a facility’s overall productivity. Faster alternatives can dramatically change that equation. As she explains, “In donation, we can do that in less than five days.” By accelerating inventory removal, warehouses can restore capacity and focus on products that generate operational revenue through picking, packing, and shipping activity. Connecting Excess 3PL Inventory with Nonprofit Demand While warehouses struggle with surplus products, nonprofit organizations often struggle to find inventory to support their missions. Abby discovered that these two ecosystems rarely connect, despite having complementary needs. The nonprofit sector is far larger and more specialized than many operators realize. As Abby explains, “There are 1.5 million nonprofits in the US, and they are so niche.” Many of these organizations rely on donated goods to run programs or serve communities. Yet access to those goods can be inconsistent. Abby notes that “80% of them need inventory.” By creating a platform that connects excess 3PL inventory with nonprofit demand, Stock helps redistribute products that might otherwise go to waste. Looking ahead, Abby sees donation as one important piece of a broader solution. As she explains, “donation is a sister channel to liquidation, destruction, recycling, and secondhand selling.” Building a full suite of end-of-life inventory options could help supply chains handle excess goods more efficiently in the future. Key Takeaways Less than 20% of inventory gets liquidated, and in some cases, the figure is closer to 5%. Shopify hosts about 4 million brands, yet roughly 90% fail within three years. Traditional liquidation can take about 16 weeks for excess 3PL inventory to leave a warehouse. Donation channels can move inventory in fewer than five days. The United States has roughly 1.5 million nonprofit organizations. About 80% of nonprofits report needing inventory to support their programs. Apparel represents about 23% of the inventory flowing through Stock’s platform. Food and beverage is the second-largest category, driven by packaging changes and expiration cycles. Cosmetics rank third among the most frequently redistributed products. Donation provides an additional channel alongside liquidation, recycling, resale, and disposal. The New Warehouse Podcast Finding a Home for Excess 3PL Inventory

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Supply Chain Data Capture Is Entering a New Era with Surgere

Mon, 23 Mar 2026 12:35:55 +0000

In this episode of The New Warehouse Podcast, Kevin Lawton speaks with Bill Wappler, CEO and founder of Surgere, live from the show floor at Manifest 2026. Surgere focuses on capturing highly accurate supply chain data and making it usable across complex logistics environments. In the conversation, Wappler shares how data-capture technologies are evolving, how massive volumes of supply chain data are reshaping the industry, and why the next frontier may involve mobile data-capture systems and AI-driven analysis. Supply Chain Data Capture Is the Foundation of Modern Logistics As warehouse and logistics technologies continue to mature, supply chain data capture has become the backbone of modern operations. Automation, robotics, and advanced analytics all depend on reliable data flowing through the system. Without that data, even the most advanced technologies struggle to deliver real operational value. Wappler explains that Surgere’s role in the industry remains surprisingly straightforward despite the complexity behind the scenes. “All we do is capture incredibly accurate data. Yeah. And share it.” The concept may sound simple, but delivering highly accurate data at scale requires sophisticated infrastructure and technology. Accurate data is now essential for companies operating in increasingly complex supply chains. Wappler notes that organizations need reliable information simply to function effectively in today’s environment. “People really need a lot of accurate data nowadays to exist in the modern supply chain; that’s what we do. We provide the data.” At the same time, the technologies used to capture that data are rapidly improving. Sensors, tracking systems, and digital infrastructure are becoming more capable and easier to deploy across supply chain networks. Managing Massive Volumes of Supply Chain Data Capturing data is only the first step. As organizations deploy more technology across their operations, the volume of data generated has grown exponentially. That scale introduces a new challenge: making the data usable. Surgere’s platform now processes enormous volumes of information generated across supply chains. Wappler highlights the magnitude of that growth, explaining that “We are doing today about 15 billion transactions a month for our clients.” At that level, the challenge is no longer simply gathering data. Instead, organizations must find ways to analyze it quickly enough to make decisions. When the data becomes too large or complex, companies risk falling behind operationally. This is where artificial intelligence begins to play a critical role. Wappler notes that massive datasets require new tools to transform raw information into actionable insights. As he explains, “The worst thing you could do, I think, is to go through deploying all of that technology. Creating all that data, but you can’t use it.” Surgere’s Agentic AI system, Sophia, was developed to address that exact challenge. By helping organizations synthesize and analyze massive datasets, Agentic AI enables the extraction of meaningful insights from the growing volume of real-time supply chain data. Mobile Data Capture May Be the Next Frontier As supply chains generate more data, the infrastructure required to capture it can become expensive and difficult to scale. Traditional systems often rely on fixed sensors installed throughout warehouses and distribution centers. Wappler believes the next evolution will involve making that infrastructure mobile. Rather than installing readers or sensors everywhere, companies could deploy mobile systems that move to the point of activity when needed. He explains Surgere’s approach to addressing this challenge: “What we are doing to overcome the cost of that is we’re making our technology mobile.” In practice, that means autonomous systems positioning themselves where data needs to be captured. When a truck arrives at a dock door, for example, mobile robots equipped with data capture tools could move into position to scan assets and shipments. According to Wappler, this shift represents a broader trend across the logistics industry. As he puts it, “I think our future in the industry won’t be fixed. It’s going to be flexible and mobile.” This flexibility could dramatically reduce infrastructure costs while improving warehouse visibility across dynamic supply chain environments. Key Takeaways Surgere captures and distributes supply chain data across complex logistics networks. Accurate supply chain data has become foundational for automation and modern logistics systems. Surgere currently processes about 15 billion transactions per month across client operations. Massive datasets require AI tools to synthesize and analyze information before it’s too late. Surgere developed an Agentic AI system, Sophia, to help organizations process and use large datasets. Traditional fixed data capture infrastructure can create cost and scalability challenges. Mobile data capture technologies may reduce infrastructure costs while improving visibility. Companies are increasingly forming data-sharing networks across trading partners to expand visibility. The next challenge for the industry is integrating many independent technologies into unified systems. The New Warehouse Podcast Supply Chain Data Capture Is Entering a New Era with Surgere

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The Buyer’s Journey for Warehouse Automation

Wed, 18 Mar 2026 14:51:32 +0000

In this episode of The New Warehouse Podcast, Kevin Lawton brings together a panel representing every side of the warehouse automation buying journey. The conversation features Christoph Buchmann, CEO of iAutomate; Mert Selchuk, Director of Supply Chain Strategy, Solutions Design, and Engineering at Staples Canada; and Rainer Buchmann, former CEO of Dematic and SSI Schaefer and current CEO of Dynamics Plus. Together, they unpack where automation projects truly begin, why many efforts stall before they start, and how buyers and solution providers can navigate complexity with better data, clearer alignment, and stronger partnerships. Where the Automation Buying Journey Really Begins The automation buying journey rarely starts with a vendor call. According to Christoph Buchmann, it begins much earlier, inside the operation itself. “Where does the buying journey begin? I would actually say it really starts with having identified a problem statement and understanding that warehouse automation is potentially a viable solution.” By the time a solution provider begins internal conversations, evaluations, and early buy-in are often already underway. Buchmann adds, “I’ve had several conversations in the past ten years where people had a fixed opinion already on what they wanted, and only through more thoughtful, deeper discussions and data crunching, they got convinced that it is not the right solution for their problem.” From the buyer side, Mert Selchuk reinforces that disciplined preparation is critical. “We identify a problem gap or an opportunity… repeatable behavior, automatable behaviors, automatable processes.” That work includes deep data analysis, WMS validation, and exhausting non-automation fixes first. The goal is clarity. Automation should support a defined need, not compensate for broken fundamentals. As Buchmann warns, “If you automate a bad process, you’ve still got a bad process. Just a very expensive one.” How the Buyer’s Journey Moves from Curiosity to Commitment Trade shows, demos, and marketing fuel curiosity, but curiosity alone doesn’t justify capital. Rainer Buchmann has seen this shift over the course of decades in the industry. “People had a fixed opinion already on what they wanted… and only through some deeper discussions and data crunching, they got convinced, ‘oh no, that maybe is not the right solution.’” More information doesn’t always mean better decisions without context. Selchuk highlights one of the biggest friction points in moving forward: time. “You’re just waiting for four weeks… just to get a number for you to plug this model that’s already there.” Early-stage tools for the automation buying journey, like Kardex StoreX and the iAutomate Configurator, that provide directional cost and ROI estimates, help teams decide whether a project is even viable before heavy engineering work begins. That speed benefits both buyers and suppliers by filtering out projects that lack alignment or budget support. Why Partnership Matters More Than Technology Successful automation projects rely on collaboration, not transactions. Selchuk emphasizes that solutions must account for the entire operational flow. “Unless I can articulate, ‘here’s how the product flow is coming into the system… and here’s how it gets out,’ this thing doesn’t go.” Partial solutions often create new bottlenecks, either upstream or downstream. Rainer Buchmann frames it simply. “Integrated automation is a journey. The project does not stop when you’ve delivered it, so be careful who you select as your partner.” Automation investments can shape operations for 10–20 years. They affect careers, resilience, and long-term flexibility. As Christoph Buchmann notes, “While the transaction is a one-time thing, that customer is investing 20 years into the infrastructure of their supply chain.” Key Takeaways Automation projects begin with clearly defined operational problems, not vendor conversations. Data validation and internal alignment happen months before solution providers are engaged. Faster, early-stage cost and ROI visibility helps qualify opportunities sooner.r Technology-first thinking increases risk and sticker shock Long-term success depends on collaborative, end-to-end partnerships Automation investments shape operations, careers, and resilience for decades The New Warehouse Podcast The Buyer’s Journey for Warehouse Automation

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