Podcasts Archives - Material Handling Wholesaler

Material Flow Optimization from K.Hartwall

Mon, 01 Jun 2026 14:34:02 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin Lawton speaks with Courtney Jackson live from the MODEX 2026 show floor in Atlanta. Courtney shares how K. Hartwall approaches material flow optimization through connected cart systems, tugger trains, and its LiftLiner solution. From ergonomics and e-commerce picking to AGV integration and ROI analysis, Courtney explains how flexible cart-based systems can help warehouses optimize movement throughout the supply chain. Material Flow Optimization Starts with Movement Hartwall’s approach centers on improving the flow of products through a facility. Courtney explains that the company’s solutions are designed to work together rather than function as isolated tools. As she explains, “What we do is really focus on material flow, with our customers.” She also notes that the systems are designed to “improve our customers’ flow, improve safety, improve efficiencies throughout the entire supply chain.” The discussion also highlighted common warehouse bottlenecks. According to Courtney, many operations are still trying to solve issues related to picking speed, accuracy, and safety. She says customers are often asking, “How can we move more product but still safely in one move?” Instead of relying solely on traditional pallet and forklift workflows, K. Hartwall positions its carts as a more flexible option. Courtney explains, “Our carts are meant to sometimes serve as an alternative to pallets, to forklifts to move just a little bit more seamlessly in an operation.” LiftLiner Systems Improve Efficiency and Safety A major focus of the conversation was K. Hartwall’s LiftLiner tugger train system. The solution allows operators to transport multiple carts or pallets simultaneously while reducing travel time across the warehouse. Courtney describes the LiftLiner as “a wonderful and unique system.” She adds, “This gives you or operators the ability to do more with less.” The material flow optimization gains become even more significant at scale. Courtney explains, “You’re able to move up to eight pallets or eight row carts in one move.” She continues by saying the system helps operations by “eliminating unnecessary travel and decreasing travel time within your warehouse.” Courtney explains the flexibility of the cart system to improve workflow efficiency. As she puts it, “That does speed up the picking process when you’re able to go, you pick from both sides.” Automation and E-Commerce Drive New Use Cases Courtney confirmed that AGVs and AMRs can work directly with the LifetLiner system. She explains, “For those companies that do have those, AGVs that can connect seamlessly to our lift liner.” She also notes, “You don’t need an operator anymore.” E-commerce fulfillment operations may see particularly strong benefits from these workflows. Courtney discussed how large facilities often lose time through long travel distances during picking operations. She explains that in major warehouses, workers may travel significant distances during fulfillment. According to Courtney, “This right here decreases the time that you’re picking by, in a significant way.” Hartwall also works closely with customers to evaluate workflows before recommending a solution. Courtney explains, “I’m getting on-site with the customers. I’m really getting an understanding of their entire process from inbound to outbound, what they’re picking, how they’re picking.” She adds that the company supports decisions with data-driven evaluations and ROI analysis to help optimize future operations. Key Takeaways on Material Flow Optimization K. Hartwall focuses heavily on material flow optimization across the supply chain The LiftLiner system can move up to eight pallets or carts in one trip Tugger train systems help reduce unnecessary operator travel time Cart-based workflows can serve as alternatives to traditional forklift movement The LiftLiner supports ergonomic picking from both sides of the cart AGVs and AMRs can integrate directly with the LiftLiner system

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Autonomous Yard Operations from YMX Logistics

Mon, 01 Jun 2026 13:14:04 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin Lawton speaks with Rock Stars Matt Yearling and Erin Mitchell of YMX Logistics, and industry analyst Bart De Muynck, live from MODEX 2026. The discussion covers technology enablement, autonomous yard operations, digital twins, safety culture, and the growing need for orchestration across the yard. The episode also highlights how YMX combines operational expertise with technology to help shippers create more value from an area many organizations still underestimate. Yard Operations Are Becoming a Strategic Priority For years, many warehouse operations viewed the yard as a secondary concern. However, that perspective is beginning to shift as distribution centers push for greater throughput and faster execution. Matt Yearling explains that yard operations now sit at the center of a larger operational challenge. As he notes, “There’s nobody on the planet that looks at the yard as a specific problem.” He adds, “It is between transportation and warehousing.” That middle ground has become increasingly important as warehouse and transportation systems improve. According to Bart De Muynck, many companies optimized transportation and warehouse execution first, which exposed inefficiencies in the yard. He explains, “We’ve optimized that. We’ve created a lot more velocity. Now the yard has become an even bigger bottleneck.” Delays in the yard can disrupt dock scheduling, labor planning, outbound fulfillment, and customer service. De Muynck compares the issue to a minor mechanical failure that stops an expensive car. As he puts it, “It’s not always the cost of something, but it’s the impact it has on your operation.” Technology Alone Does Not Solve the Problem YMX’s approach focuses on combining operations, technology, and execution rather than simply deploying software. Yearling explains that traditional yard management systems only solve part of the challenge. Instead, YMX focuses on orchestrating the entire operation through modeling, planning, execution, and visibility. Yearling explains, “It’s very clear that it’s the convergence of operations and technology, focusing on what is the problem you’re trying to solve?” He continues, “It isn’t about — let’s go and hunt for the next widget and apply it and see whether or not it works.” The company’s latest announcement at MODEX further expands that philosophy. YMX discussed its capabilities for autonomous yard operations, including digital twins, computer vision, data capture, and autonomous trucks. However, Yearling emphasized that automation still requires operational expertise. He explains, “People think it does everything, and we know it does not.” Instead of adding more assets or labor to the problem, YMX uses operational data to model and optimize yard performance. Yearling says, “Show us some data. If you don’t have the data, we will observe, we will model it.” He also notes the company focuses on “delivering on doing more with less from day one.” Strong Yard Operations Still Depend on People While automation and orchestration played a major role in the discussion, Erin Mitchell highlighted the operational culture required to support large-scale yard operations. YMX operates across the country with drivers working around the clock, making communication and safety essential. Mitchell explains, “Our customer success is our success.” She adds, “We make sure that our drivers know that their job is to make the customer successful.” The company also uses technology to strengthen communication with drivers. YMX developed an always-on app that allows drivers to provide immediate operational and safety feedback. Mitchell explains, “Our entire leadership team reads all of those app comments.” She continues, “We get that feedback in real time.” YMX also places a strong focus on workforce development and diversity. Mitchell explains that the company invests heavily in training opportunities and leadership development. The organization also works to create more opportunities for women drivers and women in logistics roles. As yard operations become more advanced, YMX believes success will depend on combining technology with engaged people, operational discipline, and continuous feedback loops. Key Takeaways Yard operations are becoming a major operational bottleneck as warehouse and transportation systems improve. YMX views the yard as a strategic layer between transportation and warehousing Autonomous yard operations still require operational expertise and oversight. Digital twins, computer vision, and data capture help optimize yard performance. Real-time driver communication plays a major role in operational safety and culture. Leadership teams review driver feedback daily through YMX’s always-on communication tools. Workforce development and inclusion remain key priorities as YMX continues to grow. The yard may represent a smaller logistics spend, but it can create a significant downstream operational impact. The New Warehouse Podcast Autonomous Yard Operations from YMX Logistics

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Warehouse Execution Systems: Optimizing People, Processes, and Automation

Wed, 27 May 2026 14:20:00 +0000

Welcome to this episode of The New Warehouse Podcast, where Kevin Lawton speaks with Mike Krabbe and Suneel Krishnaswamy from enVista live at MODEX 2026. The three of them explore how warehouse execution systems (WES) are helping operations connect automation, labor, and workflows into a more synchronized operation. From digital twins and interoperability to robotic pallet building and pick-to-light systems, enVista shares how companies can scale automation without creating disconnected systems or operational bottlenecks. Why Warehouse Automation Needs Orchestration Automation has become far more accessible for third-party logistics and warehousing. However, adding more technology also creates more complexity across operations. That is where warehouse orchestration becomes critical. As Suneel Krishnaswamy explains, “Now with that, you need something, typically a WES, that optimizes across people, processes, and automation.” A WES sits between the WMS and WCS layers to coordinate workflows across labor, robots, AMRs, and automation systems. Krishnaswamy explains, “It’ll optimize and balance all of that to get maximum throughput for the warehouse.” The conversation also highlights why interoperability matters more than ever. Many facilities now use automation from multiple vendors. Without orchestration, operations can create choke points or disconnected workflows. Krishnaswamy notes, “Having that total flow through the warehouse and optimizing it so that all the different parts of the system work synchronously… that’s the part that WES will orchestrate.” Building Automation Roadmaps Without Starting Over One major takeaway from the discussion is that companies no longer need to pursue massive “rip and replace” automation projects. Instead, many are gradually implementing automation while preserving future flexibility. Krishnaswamy explains, “They want to do it in a very cautious and risk-averse way.” That cautious approach has increased the importance of a flexible WES layer. enVista’s approach allows companies to introduce automation step by step while maintaining consistent workflows. Krishnaswamy says, “It can give you a smooth ramp-up on automation once you have a good WES in place.” The pace of innovation also continues to accelerate across warehouse automation. Krishnaswamy notes, “Since about 2015, the automation scene drastically changed. And the pace of new innovation for automation has taken off.” That rapid innovation creates pressure for operators to remain adaptable. A strong orchestration layer helps warehouses evolve without becoming locked into outdated systems or infrastructure. Digital Twins, Visibility, and Real-Time Optimization enVista also showcased its digital twin and simulation capabilities during MODEX 2026. Krishnaswamy explains, “We can set it up and do a simulation with the customer’s order profile so they can actually see what to expect from that equipment for their profile.” That visibility becomes especially valuable during seasonal peaks or changing order profiles. Instead of guessing how automation will perform, operators can validate assumptions before investing. The discussion also covered enVista’s real-time digital twin capabilities. Krishnaswamy explains, “You don’t have to walk up to the floor and see what’s happening. You’ll be getting visibility right from wherever you are.” One standout feature of enVista’s pick-to-light solution is the removal of traditional mechanical buttons to reduce operator fatigue. Krishnaswamy explains, “There’s no mechanical movement there, which obviously gives a lot more durability to the lights, and more importantly, less fatigue for the operators.” Key Takeaways on Warehouse Execution Systems Warehouse automation is becoming affordable for smaller facilities, not just large operations. WES platforms help orchestrate labor, robots, AMRs, and automation into synchronized workflows Interoperability is critical as warehouses deploy automation from multiple vendors. A WES can help companies gradually scale automation without major operational disruption. Digital twins allow operators to simulate throughput and validate automation investments before deployment. Real-time visibility improves operational awareness and helps managers make proactive decisions. The New Warehouse Podcast Warehouse Execution Systems: Optimizing People, Processes, and Automation

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Warehouse Autonomy Meets Operational Reality

Tue, 26 May 2026 15:42:47 +0000

Welcome to this episode of The New Warehouse Podcast. Michael Lawrence, Director of Sales and Business Development from Anantak, shares a different approach to warehouse autonomy. Anantak has a deep focus on brownfield-friendly deployments, vehicle-to-vehicle interaction, and customer-driven engineering. The episode also highlights how Anantak’s technology navigates facilities without requiring major infrastructure changes inside warehouse operations. Why Warehouse Operations Fit Autonomy Anantak’s approach to automation intentionally focused on structured material-handling workflows rather than trying to force autonomy into unpredictable settings. “The material handling space is a really good one. It’s a well-defined environment with operational rules and expectations, which is a good fit for autonomy. It thrives with that kind of structure.” Regarding warehouse autonomy, companies can get caught up in flashy demos and big promises. Lawrence explained that Anantak took a more practical path from the beginning. “We didn’t want to just think that we could build the perfect widget and then we’d sell a million of them tomorrow.” As he put it, “It’s not just attaching a bunch of sensors and computers to existing industrial vehicles.” The goal is to make autonomy fit naturally into the customer’s operation. Autonomous Vehicles Built for Brownfield Facilities One of the biggest differentiators in Anantak’s approach is its ability to deploy inside existing facilities without requiring major operational changes. That stood out throughout the MODEX demonstration. Lawrence emphasized this directly when discussing customer concerns around deployment complexity. “A guiding philosophy for us is that we don’t impose ourselves on the customer environment.” He continued, “We don’t require any sort of infrastructure adjustment.” Instead, the system uses multiple LiDAR sensors, depth cameras, and internally generated “breadcrumbs” to navigate warehouse routes in real time. According to Lawrence, the platform processes data from five LiDARs, two safety LiDARs, and multiple cameras simultaneously. He explained, “We fuse all that in real time to navigate the vehicles in their environment.” The system also adapts dynamically to changing operational conditions. Lawrence described how the tugger behaves similarly to a roadway vehicle. “It follows its own lane. It thinks in terms of these, like, lanes on a road.” That flexibility allows the vehicles to function in brownfield warehouse environments while using the same routes operators already travel today. Vehicle-to-Vehicle Interaction Takes Center Stage MODEX was full of impressive demonstrations, but one rarely seen, if ever, was Anantak’s autonomous forklift and autonomous tugger, both actively interacting in real time. Lawrence explained the significance of the demonstration, saying, “We believe we are showing the first ever exhibit where two autonomous vehicles are actually interacting with each other.” Lawrence explained the broader impact on warehousing, “We can get the forklifts lifting and the tuggers tugging.” The roadmap already includes advanced stacking capabilities, additional customer-specific workflows, and collaboration. “One of our principles is engineering by experience.” He added, “We want the customer to tell us what is useful for them, and then we will build to that specification on our dime.” Key Takeaways on Warehouse Autonomy Anantak has been developing warehouse autonomy solutions for approximately 11 years. The company focuses heavily on brownfield warehouse environments without requiring infrastructure changes. The autonomous system does not rely on magnetic tape, QR codes, or wall markers for navigation. The platform processes data from five LiDARs, two safety LiDARs, and multiple depth cameras simultaneously. Anantak demonstrated coordinated interaction between an autonomous forklift and an autonomous tugger live at MODEX 2026. The tugger system navigates using internally generated “breadcrumbs” and lane-based movement logic. The company’s roadmap includes advanced stacking and additional autonomous forklift workflows. The New Warehouse Podcast Warehouse Autonomy Meets Operational Reality

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Dexory Upgrades the Tallest Robot in Warehousing

Tue, 26 May 2026 15:18:50 +0000

How do you top the tallest robot in the industry? Chris Coote, Director of Product at Dexory, caught up with The New Warehouse live from MODEX 2026 to explain how the company is doing just that with its new Dexory View Adapt platform. The conversation also explores how AI-driven insights can reduce firefighting, improve visibility, and help warehouse teams shift from reactive problem-solving to proactive operational management. Moving Beyond Inventory Visibility Dexory initially gained attention for its autonomous robot that can scan warehouse inventory in real time. However, as Coote explains, the true value lies within the intelligence layer powering the platform. “That data fuels our intelligence platform called Dexory View. That’s really what customers are buying.” He also noted that the platform helps operators determine “is the right thing in the right location, with the right quantity on hand.” In addition, Dexory’s AI now detects damaged pallets, hanging shrink wrap, and damaged rack structures. This shift allows warehouse teams to move away from reactive operations. Coote explained, “The team is now problem solvers and fixers, opposed to being kind of the hunters in the warehouse.” Warehouse leaders increasingly want more than dashboards and static reports. They want actionable intelligence that improves operations immediately. Instead of manually searching for issues, operators can focus on solving problems before they escalate. Dexory View Adapt Delivers Warehouse Intelligence Dexory View Adapt represents the next evolution of the company’s platform. Rather than only showing warehouse conditions, the new offering focuses on helping operators understand why problems are happening. Coote explained, “They also have told us extensively- We need to know the why. We need to get to the root cause of these problems.” He added, “With Dexor Review Adapt, we want to take those hours and days down to minutes and seconds.” Instead of walking the floor or reviewing spreadsheets, warehouse teams can interact with the system. Coote described it this way: “You can ask those questions in Dexor Review and get an answer.” He also explained that the platform proactively identifies problems operators may not even know exist yet. “Maybe the things that haven’t broken yet, but we can see in the background might break.” Operational patterns, movement data, throughput analysis, and warehouse-specific context power the proactive notifications. Heat maps and SKU-level insights help operators understand where congestion is happening and why. As Coote summarized, “How do you get from something happening to an action as quickly as possible?” Not All Warehouses are the Same One of the most compelling parts of the conversation centered on warehouse-specific context. Dexory is not simply creating another AI chatbot layered on top of warehouse data. Coote emphasized, “This isn’t just like another chat tool.” Instead, Dexory integrates warehouse-specific operational knowledge, including WMS data, ERP systems, SOPs, and SLAs. That context matters because no two warehouses operate exactly alike. Even facilities within the same network can behave differently based on processes, staffing, and workflows. As Coote explained, “We’ve learned that not all warehouses are the same, not even in the same brand or customer.” He added, “Understanding the specifics about that site and how that behaves, you need to get down to that kind of level.” Dexory’s approach also creates opportunities for benchmarking across multi-site operations. Customers can compare performance across warehouses, regardless of different WMS environments. Key Takeaways from Dexory Dexory View combines autonomous robotics with warehouse intelligence software. Dexory View Adapt focuses on identifying root causes rather than just operational symptoms. The platform helps operators move from reactive firefighting to proactive decision-making. AI-driven storage health monitoring can identify damaged pallets, shrink wrap, and rack issues. SOPs, SLAs, WMS data, ERP systems, and operational context are integrated into the platform. The New Warehouse Podcast Dexory Upgrades the Tallest Robot in Warehousing

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Warehouse Automation Installation: Precision and Cost

Wed, 20 May 2026 13:58:19 +0000

In this episode of The New Warehouse Podcast, Kevin chats with Will Blount about the growing complexity of warehouse automation installation and why precision execution has become critical for modern facilities. Wize Solutions has spent nearly two decades supporting warehouse operations. More recently, the company has expanded into automation-focused mechanical installations for ASRS systems, dense storage solutions, and brownfield retrofits. The conversation explores how integrators, OEMs, and operators are approaching automation projects differently as facilities look to maximize existing space and minimize downtime. Warehouse Automation Installation Requires Precision As automation projects became more complex, Wize found an opportunity to expand its role. The company already had 525 team members supporting conventional warehouse infrastructure. According to Blount, about 200 employees showed strong interest in automation-focused work. He explained that pairing those experienced installers with precision training “created a recipe for success for us.” Today, Wize supports both OEMs and integrators during implementations. Blount explained, “I would say the best way to view us is as an extension of your execution team.” That role now includes receiving material, coordinating installation work, and preparing systems for commissioning teams. Brownfield Projects Are Driving New Challenges Brownfield automation projects continue gaining momentum as operators try to extend the life of existing facilities. Blount said Wize currently sees project demand split roughly evenly between greenfield and brownfield work. He explained, “Yeah, I would say, velocity-wise, probably 50/50 right now.” Blount noted that four-way shuttles, AMR-based goods-to-person systems, and dense storage technologies are creating strong market demand. He explained, “I’m seeing a big push for dense storage.” Brownfield work also introduces operational complexity. Existing facilities often remain active during installation. Floors may have major slab variance, and operators cannot afford extended downtime. Blount explained that some facilities show “four inches of variance across a 200,000 square foot” footprint. He added, “The customer oftentimes doesn’t want to shut down, right? So you have to find creative ways to plan the work, you have to find creative ways to execute the work.” How Warehouse Automation Installation Impacts Costs Many systems appear similar on the surface, but the underlying infrastructure requirements can differ dramatically. Blount explained, “You’ve got one masted AMR provider that does two bolts and shims. And you’ve got one masted AMR provider that does a jack bolt with a grout pack underneath.” He added, “Two very different installations, two very different costs to do that, ultimately providing the same results, right?” Blount described scenarios where Wize reviewed layouts and identified ways to eliminate unnecessary pallet stands or reduce rail requirements. He explained that those conversations help ensure accurate quoting and smoother execution because “the install quote is wrong, and that doesn’t help anybody.” Key Takeaways Wize Solutions evolved from conventional warehouse infrastructure into precision automation installation support. Brownfield and greenfield project demand is currently close to 50/50 Dense storage systems and four-way shuttle solutions are driving significant project activity Brownfield projects often require installations inside active operations with limited downtime The New Warehouse Podcast Warehouse Automation Installation: Precision and Cost

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Scalable Warehouse Automation from OPEX

Mon, 18 May 2026 15:24:05 +0000

Warehouse operators are under pressure to grow without expanding their footprint. In this episode of The New Warehouse Podcast, Kevin Lawton speaks with John Sauer of OPEX live from MODEX 2026. The conversation explores how OPEX is approaching scalable warehouse automation through flexible goods-to-person systems, faster deployment timelines, and new automation capabilities inside existing facilities. The discussion highlights the ways warehouses are balancing throughput, storage density, labor reduction, and flexibility in today’s landscape. Scalable Warehouse Automation Decisions Sauer explained that scalability has become one of the most common themes in customer conversations. As he noted, “I want to operate within my existing building. I want to invest in a technology that’ll scale and grow as I scale and grow.” That challenge is especially important in brownfield environments. Companies want automation that increases storage density and throughput without forcing a facility relocation. OPEX is addressing that demand through flexible systems that can scale on both storage and speed fronts. Lead times are also improving. Sauer shared that OPEX can now deliver its five-pound Sure Sort system in about three months. He also noted that goods-to-person solutions are now under a 12-month lead time. According to Sauer, “Because we can control our destiny in manufacturing and we can find efficiencies and things of that nature, we’re getting closer and closer to the quickest lead time out there for a goods-to-person technology.” He adds, “Reducing the labor, the head count for the system, is always a target for our customers.” Sure Sort® X Expands Flexibility for Difficult Products Sauer explains, “Customers still have a gap in the sortability of certain items.” The upgraded Sure Sort X system can manage products up to 20 pounds and process up to 2,100 units per hour. OPEX also added cleated induction belts and transport features to improve handling for spherical products. Sauer explained, “We always handle cylindrical items, but now we can handle round items.” The system’s flexibility opens the door for additional automation opportunities, such as supporting robotic induction workflows. He explained, “You could potentially get to human-less induction.” Precision remains critical for industries with highly variable product profiles. Sauer pointed to cosmetics as an example. He explained, “We have to be able to accurately sort an eyeliner pencil all the way up to larger tubs of facial creams.” Infinity Pushes Density, Throughput, and Temperature Flexibility OPEX also demonstrated new enhancements to its Infinity goods-to-person platform. The system uses a grid-based ASRS architecture that separates storage scalability from workstation scalability. As Sauer described it, “The scalability of throughput to storage grew significantly when we went to Infinity.” The system now supports structures up to 38.5 feet tall and can carry up to 90 pounds per bin. Sauer also shared an example of the platform’s storage flexibility. He said, “You could actually have 100,000 bins in an infinity grid feeding one station.” Another major announcement was the introduction of Tote IO functionality. The system can now eject totes from the storage structure and allow operators to work with products externally before returning them to the system. Sauer explained, “We have to eject the totes from our aisle structure and let their folks interface with it outside of our grid.” Key Takeaways on Scalable Warehouse Automation OPEX is seeing increased demand for scalable warehouse automation inside existing facilities Sure Sort X now handles round and non-conveyable products, including bowling balls and soccer balls. Sure Sort X supports products up to 20 pounds and processes up to 2,100 units per hour. OPEX introduced a powered tote supporting ambient, chilled, and frozen inventory in the same system The company stated its five-pound Sure Sort solution can now ship in about three months. OPEX said its goods-to-person solutions are now under 12-month lead times The New Warehouse Podcast Scalable Warehouse Automation from OPEX

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Cold Storage Warehouse Automation: Insights from TGW

Mon, 18 May 2026 14:43:13 +0000

This episode of The New Warehouse Podcast takes a trip down the freezer aisle. Kevin chats with Collin Russell of TGW Logistics Group to explore how frozen and refrigerated operations are approaching automation differently from traditional warehouses. Russell shares insights into labor and facility upgrades related to cold storage warehouse automation. The discussion also highlights how automation decisions increasingly center on throughput, uptime, and operational resilience rather than simply reducing labor. Cold Storage Operations Are Driving Automation Demand Cold storage warehouse automation is no longer limited to massive greenfield projects. Grocery and food service companies are actively reevaluating existing facilities while expanding into new markets. Russell explained that many operators are balancing brownfield modernization with greenfield expansion initiatives. According to Russell, “They’re trying to alleviate the labor issues that they’re having internally, especially within their frozen, temperature zones, ’cause they have a high turnover rate in there.” He added, “Not too many people want to sign up and work in minus 15 degrees Fahrenheit.” They also want to improve routing efficiency, increase outbound capacity, and serve more customers without dramatically expanding headcount. Russell pointed to growing interest in automation among major grocery operators, such as Kroger and Albertsons, as they seek to improve warehouse and transportation performance. Full Automation Is Not Always the Right First Step Many warehouse leaders arrive at trade shows looking for fully automated solutions. Instead, Russell encourages operators to match automation investments to operational realities and maturity levels. Russell explained, “Sometimes you don’t necessarily need to go that route, even if you’re just trying to dip your toe in. Sometimes it’s better to do a semi-automated option.” He also stressed that operators should avoid feeling locked into massive capital projects too early. “You can still explore some semi-automated options, dip your toe in, get a little bit more experience with the technology, and then at a later time, maybe upgrade it.” Russell described TGW’s “one-touch receiving” vision, in which products are physically touched only during unloading and loading. Everything in between becomes system-driven. Yet even with that vision, he acknowledged the industry still faces limitations around automated truck unloading, especially in frozen environments where damaged packaging and shifting freight create challenges for robotics. Reliability, Maintenance, and Commissioning Matter More Than Hype Automation success depends heavily on maintenance planning, redundancy, and realistic implementation expectations. Russell noted that many companies underestimate the long-term operational support required after installation. Russell explained, “The best scenario is, hey, let us manage it.” He also shared how TGW reduces catastrophic downtime. “We like to build in that redundancy throughout the entirety of the system so you’re not married to just one aisle, one palletizer, one set solution.” Cold-storage installations require multiple commissioning stages because steel contracts as temperatures drop. Russell noted, “Once it’s at temperature, you have to go back in and recommission it because all that steel shrank.” He offers sage advice for operators evaluating an automation provider. “Don’t just buy a product, really explore the solution.” Key Takeaways on Cold Storage Warehouse Automation Grocery and foodservice operators are heavily investing in cold storage warehouse automation to address labor shortages and increased throughput demands. Brownfield modernization projects are becoming increasingly common alongside greenfield expansion efforts. Semi-automated systems can provide meaningful operational improvements without requiring full automation immediately. Many cold storage automation projects range from $5 million to more than $200 million. ROI expectations for automation projects are typically set within 3 to 5 years. Redundancy planning is critical to minimizing downtime in automated facilities. Cold storage commissioning requires multiple phases because steel contracts as temperatures drop. Automated truck unloading remains one of the industry’s biggest long-term opportunities. The New Warehouse Podcast Cold Storage Warehouse Automation: Insights from TGW

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Lithium Forklifts: Big Joe Challenges Legacy Thinking

Wed, 13 May 2026 15:27:00 +0000

Welcome to this episode of The New Warehouse Podcast featuring special guest Martin Boyd, CMO at Big Joe Forklifts. Big Joe has long been known for its warehouse equipment, such as walkie stackers and pallet trucks. However, the company is now making a major push into larger lithium-ion forklifts designed to replace propane and diesel equipment. During the conversation, Boyd explains how Big Joe Pulse gives operators deeper visibility into charging behavior, energy use, and ROI. Big Joe Pushes Beyond Traditional Warehouse Equipment At MODEX 2026, the company showcased a sit-down counterbalance forklift powered entirely by integrated lithium-ion batteries. Boyd explained that Big Joe focuses on helping operations transition away from propane- and diesel-powered equipment without sacrificing performance. As Boyd explained, “The mentality out there is that electric products can’t do the job that propane and diesel trucks do. When in fact, the technology has evolved so much now that the electric products can do the same job and even better than internal combustion.” Big Joe even displayed an old propane forklift inside a smoke-filled box, asking attendees, “Are you still stuck in the past?” The goal was simple. Challenge long-standing assumptions about electric forklifts and show how modern lithium-ion systems now compete directly with IC trucks in demanding environments. Big Joe also displayed several new forklifts, including a 10,000-pound unit already deployed in customer operations and a new 15,500-pound high-voltage truck planned for release next year. Integrated Lithium Changes Forklift Design Boyd explained that many older electric forklifts limit flexibility and often create compromises for operators. Boyd described the difference directly, saying, “Lithium is the answer to that. It solves all the pains that lead acid brings.” He also explained how integrated lithium changes the entire design process. “It really enters a space where it gives engineers freedom to finally design a lift truck not around a box where a lead acid product would go.” Boyd noted that many operators assume electric forklifts will feel weaker or slower than propane units. However, Big Joe often sees the opposite reaction during demos. “Many times we have to detune the trucks because the trucks are too powerful or they go too fast.” The charging process also changes operational behavior. As Boyd explained, “Lithium likes to be charged often. It likes to be charged fast. I always say you’re constantly topping off the tank whenever you get a chance.” Big Joe Pulse Brings Visibility to Fleet Electrification Alongside its equipment lineup, Big Joe also introduced Big Joe Pulse at MODEX 2026. Pulse is a telemetry platform designed to help customers better understand fleet usage, charging habits, and energy consumption. Boyd explained that the system helps customers understand why certain operational issues occur during electrification rollouts. In one example, he noted, “There’s a reason why the truck didn’t last the shift because your operator in the third shift didn’t put it on a charge.” That visibility helps customers right-size batteries, chargers, and charging schedules while improving operator education. It also creates measurable financial insights. Boyd shared one of the biggest operational findings from customer deployments: “What we’ve seen is anywhere between 80 to 90% savings just in fuel alone.” Beyond fuel savings, Pulse also tracks sustainability metrics. The system can estimate reduced emissions, lower energy consumption, and broader environmental impact. Key Takeaways on Lithium Forklifts from Big Joe Big Joe is expanding beyond traditional warehouse equipment into larger lithium-ion counterbalance forklifts. The company displayed forklifts ranging from 4,000-pound to 15,500-pound capacities at MODEX 2026 Big Joe’s forklifts are fully integrated lithium-ion systems rather than retrofitted lead-acid designs. Operators often underestimate the performance of electric forklifts during initial demos. Big Joe says some electric units are so powerful they must be “detuned.” Big Joe reports customers seeing “80 to 90% savings just in fuel alone.” The New Warehouse Podcast Lithium Forklifts: Big Joe Challenges Legacy Thinking

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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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