The future of your warehouse is already here

Don't just write off every aging installation. The smartest investment in automation is often found in what you already have.

Logistics is a rewarding but challenging business. The sector is caught between geopolitical uncertainty and an insatiable appetite for greater logistics capabilities. This leads to a non-linear growth pattern, but the long-term focus must undeniably be on growth: rising volumes, increasing complexity, and customers who are becoming ever more demanding.

Expanding seems like the logical choice, but it’s no easy task. Space is scarce, permits are even scarcer if that’s possible, grid congestion is a harsh reality, and finding the right people to staff your warehouse isn’t exactly easy either.

And then, in many warehouses and distribution centers, there’s an additional challenge: equipment that has served faithfully for years is starting to malfunction, spare parts are no longer in stock or available, and your supplier stopped supporting the software long ago.

Many logistics entrepreneurs see only one way out: shut everything down and start over. That’s understandable. But it isn’t always the wisest choice. It requires significant investment, a lot of time, and a great deal of organization. The operational impact is significant, and downtime costs a fortune.

For many companies, there is a better option: a retrofit. It preserves and improves what has value and goes further where necessary. The vast majority of our customers can continue using their existing automation systems for years to come, often resulting in significant additional capacity, reliability, and increased efficiency.

A targeted retrofit can take many forms: from purely technical modifications—such as new motors, sensors, PLCs, safety components, software, or interfaces, to more functional changes involving additional conveyors, a different approach to spare parts, or even an adjustment to the workflow with a redesigned packing and picking zone. Sometimes, just one zone—or one critical line—is enough to make a difference.

In that regard, it’s better not to start by asking, “What can we replace?” Instead, ask: “What still has value? Where are the risks? And what changes will truly take our system to the next level?”

You won't find the answers to those questions just in a conference room. You also need to ask them of the people who work with the system every day.

Be sure to talk to the people who are responsible for maintaining the system. That always provides additional insights. For example, our service calls reveal patterns, and preventive maintenance helps us identify wear and tear.

This isn't just some romantic notion about old systems. A retrofit may seem less spectacular than an all-new installation, but by extending the useful life of your existing systems, it often makes a much greater financial impact.  

Sven Laureys
Head of Solutions Engineering, E’Log Automation