Automation for Intralogistics: A Practical Perspective

In my work, I have seen firsthand how smart automation transforms intralogistics. Faster deliveries, real-time tracking, and flexible production are becoming the new standard in supply chains. Meanwhile, companies must navigate labor shortages, skill gaps, and rising demands for efficiency and sustainability.

Automation is key to addressing these challenges, keeping operations accurate, scalable, and reliable. In my previous post, Automation, Networking and Sensors in Intralogistics, I looked at how industrial networks, sensors, and traceability systems are integrated into everyday warehouse operations.

Let me share some additional thoughts on five key areas of automation technology that continue to shape these processes.

1. Digitized controls architecture

Modern industrial networks make connecting devices to control systems on conveyors, automated storage systems, and robotic platforms easier. Open standards like IO-Link reduce installation by minimizing sensor wiring and improving access to diagnostic data. Networking also makes system expansion and device replacement faster and simpler. I have found that this approach streamlines installation and reduces troubleshooting time when issues arise.

Seamless device connectivity through modern networks enhanced by IO-Link masters and hubs reduces complexity, speeds up installation, and simplifies troubleshooting.

2. End-to-end traceability

Tracking the location of each package or product at every stage in the facility is key. Whether using RFID or a code reading solution like barcodes, DMC codes, 2D codes, clear identification ensures the correct handling and movement of goods. In my experience, systems that maintain accurate traceability contribute to improved order accuracy, better transparency, and a smoother flow of operations.

Real-time tracking with RFID ensures every package is where it should be, reducing errors and improving process transparency.

3. Fast-paced object detection

A range of sensors including photoelectric, inductive, ultrasonic, and capacitive types, detect items in real-time. Integrated with conveyor systems and storage equipment, these sensors monitor objects' presence, position, and movement. I have observed that accurate object detection leads to more reliable process controls and better overall performance in handling tasks.

Photoelectric sensors detect objects, increasing throughput and preventing bottlenecks in high-speed operations.

4. Condition monitoring of equipment

Preventing unplanned downtime is important for maintaining smooth operations. By continuously monitoring factors like vibration, temperature, and pressure, condition monitoring systems alert operators to potential issues before they result in a breakdown. This proactive approach extends equipment life and ensures steady performance across a facility. Many companies start with condition monitoring as the first step towards predictive maintenance and improving Overall Equipment Effectiveness.

Continuous monitoring with condition monitoring sensors on conveyor belt motors prevents costly downtime and keeps equipment reliable and productive.

5. Vision-based systems

Camera systems support various applications, including code reading, quality assurance, palletizing, picking, placing, and sorting. Such systems improve automated handling of products, ensuring accurate identification and placement. For instance, in-line inspection detects damage to goods or packages, minimizing faulty deliveries. In addition, AI-enhanced 3D vision enables collaborative and industrial robots to recognize and pick objects of varying shapes and positions. Vision technology is increasingly important for traceability, object detection, and quality control in intralogistics processes.

AI-powered machine vision enhances automation, making picking, sorting, and quality control more accurate and adaptable.

In summary, these technologies play a key role in future-proofing operations such as conveying and transporting, storage and retrieval, and robotic sorting and picking. I'll take a closer look at these topics with real-world examples in future articles.

Want to learn more? Access our free Intralogistics Automation Guide: From shelf to shipment to discover how sensors, networking technology, and traceability solutions can boost your warehouse performance.