AutoStore Increases Storage Capacity by 300% for Automotive Spare Parts Distributor

Based in Germany, Emil Frey Logistik GmbH specializes in automotive spare parts logistics, managing small parts kits for various auto manufacturers. In 2023, to support business expansion, the company implemented AutoStore both at their new Kassel site and at their existing Lehrte site.

AutoStore, empowered by Kardex, has delivered high-density automated storage at both sites. The tailored, scalable systems efficiently handle Emil Frey’s growing spare parts volume and maximize the use of their space.

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The Challenge: Business Growth Outpaces Traditional Warehousing

Managing growth across two major distribution centers presented Emil Frey Logistik with significant operational challenges. The existing 40,000 m² (430,500 ft²) Lehrte facility needed modernization to handle increasing order volumes, while the new 26,000 m² (280,000 ft²) Kassel site required an automated solution that would modernize operations and optimize space from day one.

Traditional warehousing approaches couldn't deliver the necessary combination of high-density storage, operational efficiency, and speed required for the company's growth trajectory. The distribution centers needed a scalable system that could maximize storage capacity in both facilities, while simultaneously improving order fulfillment speed and creating a more ergonomic working environment for employees managing thousands of automotive spare parts.

The Solution: Integrated Automation for Streamlined Operations

Today, Emil Frey Logistik's distribution centers have advanced AutoStore systems powered by high-speed Robots and intelligently designed Grid structures. Each system features distinctive elements designed for site-specific requirements:

Lehrte facility:

• 46,000 Bin storage capacity managed by 13 R5 Robots
• Five ergonomic workstations (CarouselPorts) for efficient parts handling
• Integration with existing facility infrastructure
• Space optimized for brownfield implementation

Kassel facility:

• 29,000 Bin storage capacity operated by 13 R5 Robots
• Four CarouselPorts for streamlined order processing
• Integrated conveyor technology for enhanced Bin movement
• Purpose-built for greenfield deployment

Battery-powered, energy-efficient R5 Robots move across the aluminum grid structure, accessing Bins stacked in multiple layers. They retrieve, sort, and deliver Bins to ergonomic workstations (CarouselPorts) for efficient order-picking and refilling operations. Multiple Robots can perform the same tasks, ensuring operations continue if any unit needs charging or maintenance — this built-in redundancy helps achieve 99.76% availability while delivering the market's fastest order fulfillment per square meter.

The flexible Grid design allows for system expansion during ongoing operations, supporting Emil Frey Logistik's growth trajectory without disrupting daily activities. The Kassel site's integrated conveyor system further enhances Bin movement efficiency, enabling seamless material flow throughout the facility.

Key benefits: Scalable and Flexible Efficiency

The AutoStore implementation delivered significant operational improvements across both distribution centers, addressing key business challenges while supporting future growth. Key benefits include:

• Storage density: With AutoStore’s cube-based design, Emil Frey Logistik has improved the storage density in its warehouses by 300%.
• Reduced labor requirements: The automated system has minimized manual walking distances and repetitive tasks, creating a more ergonomic work environment.
• Scalable and modular: AutoStore’s cube-based design allows for easy expansions without disrupting operations, meeting Emil Frey Logistik's future growth needs.
• Consistent reliability: AutoStore provides 99.76% uptime, ensuring stable operations, even during peak periods.

Emil Frey Logistik can now confidently and efficiently handle increasing order volumes in a more productive, worker-friendly environment.

Success Through Automation

The implementation of AutoStore across Emil Frey Logistik's distribution centers demonstrates how intelligent automation can transform spare parts logistics. Working with AutoStore’s implementation partner, Kardex, the company achieved a solution that not only maximizes operational efficiency but also creates a foundation for sustained growth. "The experienced team at Kardex impressed us with its professional expertise in designing tailor-made, innovative overall solutions," noted Alessandro Fabris, Project Manager at Emil Frey Logistik.

This successful collaboration between Emil Frey Logistik, AutoStore, and Kardex has created highly efficient distribution centers that combine advanced robotics with smart use of space. Emil Frey is now confident that they can maintain exceptional service levels and meet rising customer demands.

Project Specifications

• Installation type: Greenfield (Kassel site); Brownfield (existing Lehrte site)
• Robots: 13 R5 Robots per site
• Workstations (Ports): 5 CarouselPorts at Lehrte site; 4 CarouselPorts at Kassel site
• Bins: 46,000 Bins (Lehrte site), 29,000 Bins (Kassel site)
• Integrated technology: Bin conveyor technology (Kassel site)
• Implementation partner: Kardex