11.04.2025
How automation drives efficiency in intralogistics
Insights from Balluff’s Intralogistics and Robotics Expert Tom Knauer
Every day, logistics and manufacturing companies face increasing demands for speed, accuracy, and cost efficiency. Warehouse operators and production managers struggle with workforce shortages, unexpected downtime, and the challenge of managing large volumes of goods efficiently. Many companies are turning to automation to stay competitive, leveraging sensor technology and robotics to streamline their processes.
To better understand how automation is transforming intralogistics and the role Balluff plays in supporting these advancements, we spoke with Tom Knauer, Global Market Segment Manager at Balluff. He shares his perspective on the challenges businesses face, how automation is being implemented effectively, and where the industry is headed.
Tom, could you share a little about your background and what excites you most about your work at Balluff?
Of course. I work closely with customers across different industries to identify their automation challenges and to develop innovative solutions that improve efficiency and reliability. My focus is ensuring that our sensors and networking products enhance processes and scalability through our automation solutions in intralogistics and robotics. Over the years, I’ve worked with partners in the automotive, packaging, and intralogistics industries to enhance their automation strategies.
What are the biggest challenges your customers face in intralogistics today?
Companies are dealing with several pressing challenges: labor shortages, rising costs, and the increasing complexity of supply chain operations. The need for speed and accuracy in intralogistics has never been greater, yet many businesses still rely on outdated processes that make it difficult to scale effectively.
One of the most common pain points we see is traceability. Operations need to know exactly where their goods are at a given time to reduce errors and inefficiencies. Additionally, the reliability of equipment is crucial. Unexpected failures lead to costly downtime and disruption. That’s where automation can make a real difference.
How does Balluff’s technology help companies tackle these challenges?
Our solutions are designed to address these specific pain points. For example, RFID technology improves traceability by enhancing precise tracking of packages or goods throughout the supply chain. This helps reduce errors and increases inventory accuracy and therefore streamlines workflows.
Another compelling aspect is condition monitoring. Our sensors detect potential issues on conveyor belts, motors, robots and other critical equipment before failures occur. This reduces unplanned downtime and maintenance costs. Instead of reacting to breakdowns, companies can take a proactive approach and ensure continuous operations.
By embracing technologies like IO-Link, RFID, and condition monitoring, many of our industry partners have increased process reliability, optimized material handling, and improved decision-making across their operations. We're excited to see how these strategies can strengthen your business and drive sustainable improvements.
Tom Knauer, Global Market Segment Manager at Balluff
You mentioned automation making a difference in efficiency and accuracy. What role does robotics play in intralogistics today?
Robots become essential for handling repetitive, labor-intensive tasks such as sorting, material handling, and palletizing. At Balluff, we support these applications with precision tracking and positioning solutions that enable robots to function with high accuracy and reliability. Another example is the use of inductive couplers for contactless transmission of power and data - particularly valuable for automating gripper changes and making them more efficient.
Beyond efficiency, sustainability is a key concern in modern logistics. Which solutions help companies become more sustainable?
Sustainability has become a major driver of change. Our designs are energy-efficient from the ground up. This minimizes power consumption while ensuring optimal performance. But it doesn’t end here. Intelligent automation solutions also help businesses use fewer resources by improving their workflow efficiency and also reducing waste.
Another example is predictive maintenance.. By extending the lifespan of equipment and preventing unnecessary replacements, we help companies reduce industrial waste, improve their environmental footprint and optimize resource usage.
What are the biggest hurdles companies face when adopting automation, and how can they overcome them?
One of the biggest challenges is ensuring precision in high-speed environments. Intralogistics operations rely on real-time data to function effectively, and our sensors provide the accuracy needed to maintain process stability.
Another key issue is handling vast amounts of data. Many businesses struggle to process the information required to optimize their workflows. Our technologies simplify data collection, transmission and visualization, turning raw data into actionable insights that support better decision-making.
Can you share a success story where Balluff’s solutions really made a difference for a customer?
Absolutely! One of our customers, a global logistics provider, implemented our RFID tracking system to improve package traceability. This reduced manual scanning efforts by 40% and significantly enhanced throughput.
In another case, a manufacturing facility using our IO-Link products cut energy consumption by 20% on their conveyor belts and simplified maintenance processes with less cabling and easier troubleshooting thanks to point-to-point connection. These are just two examples of how automation delivers tangible results for intralogistics users.
Looking ahead, what trends do you think will have the biggest impact on robotics and intralogistics? And how is Balluff staying ahead of the curve?
Automation is becoming increasingly data-driven. Predictive analytics, machine learning, AI and “big data” are shaping the future of logistics. This is where IIoT capability and condition monitoring play an important role.
Sensors and software rely on data gathered through IIoT and analyzed through AI-based anomaly detection to recognize patterns and to react in advance to potential issues. At Balluff, we are actively investing in these areas to ensure that our solutions remain the forefront of innovation.
Another important trend is adaptability. Businesses need automation solutions that can scale as their operations grow. Our solutions are modular, allowing our customers to implement just one component for a specific task, or to choose an entire solution for their use case. It also allows customers to integrate new technologies without major overhauls, thus making sure to have the necessary flexibility for the future.
If a company is thinking about optimizing their operations with automation, what’s the one piece of advice you’d give them?
Think beyond immediate automation needs and focus on long-term scalability. Solutions like RFID for tracking packages or components, and condition monitoring for predictive maintenance will provide immediate benefits. However, they will also set the foundation for future efficiency gains in the interplay with other yet to come solutions.
Choosing a technology partner that understands industry challenges and provides solutions is crucial. At Balluff, we focus on delivering the right tools to help businesses operate smarter and more efficiently, ensuring they are well-equipped for the future. I’m excited to see where the journey takes us!
Thank you, Tom, for these insights on the world of intralogistics and automation. We are looking forward to seeing how the industry continues to evolve!
