Chinese robotics company Geek+ has co-developed with Dutch firm WSR a smart mixed case palletising system combining autonomous mobile robots (AMRs) and an intelligent palletising algorithm.

WSR provides intelligent warehouse management tools. The combination with AMRs can help warehouse operators systematically handle the processing of multiple outbound orders in an efficient, safe and flexible way.

Lit Fung, vice president at Geek+, said: “We are thrilled to work together with WSR to provide a tool that targets every aspect of the outbound logistics process, from how goods are stored and moved around the warehouse to how pallets are stacked, streamlining processes by eliminating the need for re-palletisation, and optimising overall space utilisation.”

Based on real-time demand, Geek+ AMRs optimise the movement of ordered goods between the storage area and picking station. At the picking station, WSR’s intelligent algorithm helps warehouse operators stack cases of varying weight, height, width and so on in an optimal way.

Taking warehouse automation one step further, it allows operators to streamline logistics processes inside the warehouse and ensure agile supply chains through the efficient use of truck space.

“Together with Geek+, we provide a full framework for the changing market requirements,” said Marcel van Schijndel, CEO of WSR. “Innovative mixed palletising in effect serves one single goal: to optimise the customer’s supply chain with efficient, flexible and affordable automation.”

There are four key components – storage area, buffer area, case picking area and loading area.

The storage area is built on multiple layers using high-density racking and bulk lifts for more storage capacity. After inbound processing, pallets of incoming goods (donor pallets) are stored in high-density racking. Donor pallets are then moved horizontally by four-way shuttles and vertically by lifts.

The system flexibly solves bottlenecks caused by rapid changes in required throughput. With no need for wires and long installation periods, the number of shuttles can be flexibly adjusted to handle changes in required throughput, and peak values can be changed using the system’s scheduling tool.

Upon receiving the outbound order, items of high outbound volume go to a buffer area between the storage area and the picking station. Upon registering an incoming order, a picking robot picks up the donor pallet from the storage area and moves it to the buffer area for temporary storage. At the buffer area, picking robots streamline the movement of pallets, ensuring the smooth supply and optimal sequencing of source pallets to the picking station.

At the picking station, an operator picks cases from a donor pallet and stacks them on an order pallet based on a pre-calculated stacking pattern. The user-friendly interface provides the operator with information on outbound orders such as required type and quantity of goods, and the SAT laser pointer specifies case placement.

If one type of good is included in different orders, picking robots will move the donor pallet of that good to the next station, and new donor pallets containing other SKUs will automatically arrive at the original picking station for continued order picking. The remaining items that do not require further picking will go to the storage area, creating a dynamic transit cycle.

At the loading area, optimally stacked pallets are loaded onto trucks by autonomous forklifts without the need for re-palletisation. By optimising how pallets are stacked, it improves truck space use, lowering the overall transport costs. The algorithm enables efficient organisation and order sequencing of large-scale, mixed case combinations. It can be tailored to fit actual business needs for allocation and priority management, making a tool applicable to a wide range of industry scenarios.

Geek+ has 300 global customers and has sold more than 20,000 robots worldwide. Founded in 2015, it has over 1000 employees and is headquartered in Beijing, with offices in Germany, UK, USA, Japan, Hong Kong and Singapore.

Founded in 2014, WSR develops and supplies de-palletising and mixed palletising technology that make logistics more efficient, flexible and cost-effective. The firm is headquartered in Deventer in the Netherlands and has partners and resellers in Sweden, Italy, Lebanon, Spain and the USA.