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This article is part of our SME Corner, offering insights from our subject matter experts to guide you on your warehouse automation journey.

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The future of warehouse technology is already here. Advanced automation solutions like Autonomous Mobile Robots (AMRs) and Automated Storage and Retrieval Systems (ASRS) are transforming business operations with game-changing efficiency, improved accuracy, and enhanced inventory management.

These systems integrate well into existing (brownfield) warehouses, enabling businesses to reconsider the need for a new (greenfield) site. That’s not to say that retrofitting a brownfield warehouse doesn’t come with its own unique challenges and opportunities. This guide offers smart strategies and practical tips to help you navigate the complexities of implementing advanced automation into your current space.

1. Maximize Existing Investment:

Automating a brownfield site as opposed to moving operations to a new facility allows you to enhance your current infrastructure, maximizing the return on existing investments without the need to start from scratch. This approach is more conducive to rolling out upgrades gradually, avoiding the need for a large upfront setup. With advanced automation systems like ASRS, you can make full use of your building’s height for storage, achieving equal or even better operational performance in a smaller footprint.

2. Minimize Downtime and Disruption:

Automating a brownfield warehouse allows businesses to avoid the downtime typically required when building or relocating to a new facility. This enables continuous operations without the hassle of juggling both the old and new sites at the same time.

However, implementing automation in a brownfield warehouse does come with challenges, as adding automation to one area while still fulfilling orders requires careful planning. A strong distribution network to manage extra throughput can help, though not all businesses have this luxury. This is why businesses are increasingly adopting modular robotic systems for their ability to be installed within a few months, unlike legacy systems that use heavy mechanization that are slower to install and harder to scale.

3. Reduce Environmental Impact:

Keeping brownfield sites in action is a win for sustainability. It’s resource-smart, waste-conscious, and keeps emissions from new construction in check. Plus, it’s a win for smart land use, preventing urban sprawl and protecting ecosystems in the process.

Adding automation to a brownfield site comes with its fair share of challenges. Here are some important things to keep in mind to make sure everything runs smoothly and reliably:

1. Floor Levelness

Advanced automation systems demand a higher level of floor flatness than manual operations. How flat? Well, that depends on the specific type of automation you’re using. Different systems have different requirements when it comes to floor smoothness.

Automated vehicles and robots rely on sensors and programming to navigate through a warehouse. Even small variations in the floor surface can cause issues like poor traction, misalignment, or vibration, which could reduce the efficiency or accuracy of these systems.

Modern warehouses, especially those constructed in the last decade, usually have superior floor flatness and often need minimal remediation. However, in older buildings or those that housed heavy equipment, floor settling can pose challenges for technologies with strict flatness requirements. This may lead to needing some serious floor repairs or even having to put in a brand-new one.

AMRs with advanced navigation sensors and Automated Guided Vehicles (AGVs) that follow routes marked by magnetic strips, colored tape, or QR codes excel in adapting to different floor environments. In contrast, ASRS offer higher degrees of throughput and storage performance, but use tall, heavy racks that require flatter surfaces to ensure reliable performance.

To minimize floor remediation, look for systems with lenient floor requirements. This consideration is essential when exploring automation options. Mobile ASRS, like the Exotec Skypod system, stand out in this area, typically requiring only minor floor adjustments, such as simple grinding down high spots.

2. Space Constraints

When installing systems with tall storage racks, it’s important to consider your ceiling constraints, such as varying heights or low-hanging obstructions. Working around existing columns or walls in older facilities can also be tricky. Businesses should prioritize systems that are flexible enough to navigate these obstacles without sacrificing performance.

The key to this flexibility is separating throughput (material handling vehicle or robot movement) from storage operations. When vehicles or robots aren’t tethered to other equipment, they can move freely between storage racks and picking stations, making the system more adaptable to the warehouse layout and reducing the need for major structural changes. This can even open the door to a single system being able to operate between rooms, with only a small opening needed for material handling vehicles or robots to move through.

3. Load-Bearing Capacity

The warehouse floor needs to be strong enough to handle the weight and movement of automated equipment. If it can’t, you might have to reinforce it, which isn’t cheap.

It’s a good idea to prioritize systems that go easy on the floors. Lightweight robots and vehicles that can handle most inventory without heavy machinery like cranes or elevators are ideal. It’s also important to compare the weight of different storage rack systems and choose ones with lighter racks, as these are often the heaviest part of an automation setup.

4. Floor Surface Condition

The warehouse floor needs to be durable enough to handle the heavy traffic of automated machinery and resist wear and tear. It should also have the right amount of grip to prevent wheels or tracks from slipping while still allowing smooth movement for the equipment.

For businesses automating a brownfield site with existing floor constraints that cannot be relocated, such as expansion joints, it’s crucial to prioritize systems that can be built around these obstacles efficiently.

5. Integration with Existing Systems

One of the main hurdles in implementing automation in brownfield warehouses is the challenge of integrating new automation systems with existing systems and infrastructure. To tackle this challenge, businesses need to take a close look at their current systems, find where they can connect new technology, and pick automation solutions that can easily work with what they already have.

REST-based APIs (Representational State Transfer) are web services that allow communication between systems. This popular technology is relatively flexible, lightweight, and easy to use and the most advantageous way to facilitate communication between new automation technologies and existing Warehouse Management Systems (WMS) or Enterprise Resource Planning (ERP) systems.

Automating brownfield sites can be challenging, but the benefits make it worth the effort for businesses looking to improve efficiency and extend the life of their facilities. The Exotec Skypod system offers a smart solution for modernizing these spaces. Its lightweight robots and modular racks help reduce the need for major floor modifications. The flexible design easily adapts to space limitations, integrates smoothly with existing systems, and enables fast installation within months, not years,

Discover how the Skypod system can transform your facility by exploring our 3D warehouse tour.