Balluff and Kardex deliver fully operational AutoStore system in just six months — a new standard in speed and scalability

Balluff, Inc., a global leader in industrial automation, has set a new benchmark for rapid deployment in warehouse automation, going from contract signing to a fully operational AutoStore system in just six months – without major infrastructure upgrades or operational downtime.

With increasing fulfillment demands and a need to replace aging carousel technology, Balluff sought a solution that could not only meet today’s operational challenges but also scale for tomorrow’s growth. The answer came in the form of a tailored AutoStore system powered by Kardex, delivered in record time and designed to fit seamlessly within Balluff’s existing facility in Florence, Kentucky.

“We needed a fast, future-ready solution – and Kardex delivered,” said Steve Duncan, Quality Assurance and Lean Manager at Balluff, Inc. “The project was completed on time and under budget. Kardex was in lockstep with us throughout, and their professionalism and innovation exceeded expectations.”

Rapid Results with Zero Disruption

Balluff and Kardex began the project with a clear vision: implement a high-density automated storage and retrieval solution that would streamline operations – without halting them. In just six months, the site was transformed with an advanced AutoStore grid featuring 20,100 bins, 7 AutoStore Red Line Robots, 1 conveyor port, and 3 carousel ports, fully integrated with Balluff’s SAP system.

Even more impressive: the installation required no major facility renovations, thanks to creative design strategies and a phased implementation plan that maintained business continuity from day one.

Innovation Through Firsts

The speed of execution was matched by a series of industry-first design elements that maximized both time and space:

• Cross-building system design, with the AutoStore on one side of a wall and ports on the other
• Use of seismic bracers instead of columns, freeing up floor space
• Extension of the service grid into an office area, creating a more integrated, ergonomic environment

Results That Speak Volumes

Since go-live, Balluff has seen a 177% increase in throughput – a dramatic jump in performance that positions the company for long-term scalability. The compact, high-density layout has also optimized storage capacity, while employees report smoother workflows and improved ergonomics.

“Balluff challenged us to move quickly and think creatively,” said Mitch Hayes, President of Kardex Solutions. “This project proves that with the right team and vision, speed doesn’t come at the cost of quality – it amplifies it.”