As customer expectations soar and order complexity rises, even the most advanced warehouse automation systems, like ASRS (Automated Storage and Retrieval Systems) and GTP (Goods-to-Person), are being pushed to their limits. While these technologies have revolutionized warehouse efficiency, the explosion of eCommerce and demand for rapid, customized fulfillment are revealing new operational constraints.
ASRS, in particular, has emerged as a trailblazer in modern logistics by minimizing reliance on manual labor and boosting efficiency and profitability. Reflecting this momentum, the ASRS market was valued at $8.7 billion in 2023 and is projected to reach 12.7 billion by 2028. It's growing at a compound annual growth rate (CAGR) of 7.9%, according to MarketandMarkets.
The Challenge: Scaling ASRS Without Sacrificing Productivity
ASRS is often the backbone of modern fulfillment, but scaling it isn’t simple. For shuttle- based systems, expanding capacity means constructing new aisles, racks, and shuttles. This significantly increases footprint, infrastructure, and cost. And in many cases, this growth adds storage capacity without addressing throughput limitations.
A more cost-efficient approach involves increasing the number of open orders at GTP workstations. Traditional systems typically support four to 30 open orders, which helps reduce tote presentations and improves ASRS efficiency. But this only works up to a point. As the complexity of orders and the variety of SKUs increase, traditional put walls and put-to-light systems result in excessive scanning, increased walking, and heightened fatigue among workers. This trend ultimately limits overall productivity.
The Solution: BG Amplification
BG Amplification solves these modern fulfillment challenges by delivering upstream and downstream efficiencies that amplify the value of your existing systems. Whether paired with ASRS, GTP, or other automation, BG Amplification boosts throughput, productivity, and order accuracy; without the need for massive infrastructure changes.
BG Robotic Put Wall: Optimized for eCommerce
The Automated Put Wall from Berkshire Grey, driven by cutting-edge AI-enabled robotics, enhances the automation of eCommerce order consolidation and returns processing. By replacing manual put walls and conventional linear sorters, the Put Wall integrates seamlessly with complementary technologies, thereby maximizing warehouse efficiency.
- Up to 288 destinations with throughput up to 12,00 units per hour (uph)
- Modular scalability to match dynamic order profiles
- Minimal footprint and fast deployment for rapid ROI
Why it matters: By dramatically expanding the range of available destinations, you effectively reduce tote lag time, alleviate the physical demands on the Automated Storage and Retrieval System (ASRS), and empower pickers to manage a greater volume of orders per presentation, all without overwhelming them. This means more fulfillment capacity with less infrastructure and fewer costly upgrades.
BG Robotic Sortation: Built for Store Replenishment
Robotic sortation systems like those from Berkshire Grey are built to evolve with your operation. Their Modular hardware and continuously updated software integrate seamlessly with automated storage and retrieval systems, boosting throughput and reliability. With near-continuous uptime and minimal disruption during component issues, robotic sortation ensures your ASRS runs smarter, faster, and more efficiently.
- 52-120 sort points and 78-180 destinations with 1,800 - 3,000 units per hour (uph)
- Up to 228 destinations and 30,000 uph with 24/7 operations
- Best-in-class container utilization
- Automated takeaway for continuous, efficient workflows
Why it matters: This solution enables a zero walking pick-and-pack process, reducing fatigue and increasing accuracy. By eliminating the need for item singulation or manual scanning, pickers can efficiently fulfill complex orders with a single touch. This innovation streamlines the process, minimizes labor strain, and reduces the likelihood of human error.
Businesses transitioning from manual or traditional systems can achieve up to a 60% reduction in labor requirements, all while enhancing throughput and expanding SKU coverage.
Supercharge Your ASRS Efficiency
As mentioned above, traditional GTP systems max out at 20-30 open orders, severely limiting how many active picks can be fulfilled at once. BG Amplification scales that up to 10x more destinations, scaling to as many as 288 open orders simultaneously, expanding the number of destinations a single SKU presentation can serve. This empowers pickers to fulfill more orders per tote and reducing the need for repetitive, inefficient bin movements.
Key benefits:
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More items picked per bin presentation: A single bin presentation at the BG Robotic Put Wall can fulfill as many as 288 orders, compared to 1-4 orders per trip.
- Less waiting for totes to cycle: With more available order destinations, SKUs don't need to shuttle back and forth as often between the ASRS and the workstation.
- Reduced picker fatigue and idle time: Automation minimizes manual sorting, creating smoother, faster workflows.
- Greater order accuracy from less cognitive load and fewer manual validations
Crucially, BG Amplification does not require expanding ASRS infrastructure or building external buffers. It integrates directly into existing systems, even in setups where totes can’t exit the ASRS zone, saving both money and space.
Unmatched SKU Flexibility
Where traditional automation often struggles with irregular or delicate SKUs, BG Amplification excels. It’s designed to handle:
- Smalls parts
- Round or rolling items
- Non-standard packaging
This allows warehouses to automate a broader portion of their inventory, reducing manual interventions and increasing the overall effectiveness of your fulfillment operation.
Intelligent Execution: The Power of WCS + WES
Today’s warehouses need more than just automation, they need intelligent execution. BG’s Warehouse Control System (WCS), when combined with Conveyco’s New Dawn Horizon Warehouse Execution System (WES), delivers a unified platform for intelligent automation.
This integration enables:
- Streamlined workflows and reduced labor costs
- Higher oder accuracy and faster cycle times
- Real-time visibility for proactive decision making
- Seamless coordination across automation and manual processes
- Quick adaptation to shifting demand and SKU profiles
Proven Results:
- Up to 99% inventory accuracy
- 20-30% increase in picking efficiency
- 25% reduction in shipping labor costs
Do More with Less - And Do It Smarter
BG Amplification isn’t just about increasing capacity. It’s about amplifying every part of your system, from picker workflows to sortation logic to SKU handling, and doing it without massive capital investment. If you are prepared to enhance the performance of your existing Automated Storage and Retrieval System (ASRS), Goods-to-Person (GTP) solutions, or overall automation infrastructure, consider BG Amplification as your pathway to success. Consult with your Systems Integrator to initiate the process today!
