Exotec SAS today launched the next generation of its Skypod automated storage and retrieval system, or ASRS, with higher performance, improved storage density, and advanced software features.
The Skypod system consists of autonomous mobile robots (AMRs) that drive along the warehouse floor and climb the storage structure to acquire and store totes. The Skypod AMRs bring items to Exchangers, pick and replenishment stations where a human operator pulls the appropriate SKU for a customer order.
The Exchanger stations improve working conditions for operators by reducing their need to walk several miles per day, said Exotec.
The complete system also includes order movers (pack-out box queues) and autonomous conveyors that hold totes until they can be returned to the storage array. The Exotec warehouse management software manages the entire process.
Exotec expands and adds storage capabilities
Exotec said it has found success in several market verticals, including e-commerce, grocery, retail, healthcare, and industrial. The company has deployed the Skypod solution to more than 20 customers, according to Arthur Bellamy, chief revenue officer at Exotec.
In October 2024, Exotec expanded its North American headquarters in Atlanta in October 2024 with 37,000 sq. ft. of additional space. Exotec is a 2024 RBR50 honoree for its deployment of Skypod at automotive customers.
The Next-Gen ASRS comes with several design improvements including a new and more compact Skypod robot, a workstation for robot-to-robot picking, a high-throughput Exchanger, and denser storage.
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Next-Gen Skypod includes features for throughput
Exotec said its Next-Gen system offers several advantages over the current generation, including an integrated buffer, perfect sequencing, and streamlined pick-and-pack capabilities. The integrated buffer handles buffering within the system itself.
The company touted some of the new features, including:
- Ability to handle both eaches (individual unit) and case picking, making the system to be more flexible in handling different order types.
- 30% higher storage density compared to the previous generation. The new system is more compact and space-efficient, and able to fit into smaller warehouses.
- Elimination of conveyors and depalletizing/repalletizing machines. Boxes can be stored on trays to be buffered within the storage array, simplifying the overall warehouse design and reducing complexity.
- Improved sequencing capabilities: The robots can sequence boxes directly on the floor, without the need for complex conveyor loops or software to rearrange the order.
- Ability to buffer the right-sized carton/container at the exact time it’s needed for order picking. This helps optimize package sizes and reduce waste.
- Faster picking speed, up to 50% faster than the previous generation.
The Next-Gen Skypod can handle both eaches and case picking, which Exotec positions it to better address multichannel needs with a single system. It also natively supports several value-added logistics workflows.
After order preparation at the Workstation, completed or semi-completed orders are automatically stored within the racks until they are ready for outbound or further consolidation. This can reduce the need for staging areas or external buffer systems. For outbound operations, the Skypod ensures accurate sequencing, asserted Exotec.
Robots and the Exchanger work together to group and deliver orders in a specific arrangement for outbound routing. This precise control enables efficient loading of pallets, containers, or trucks according to delivery routes, store planograms, or other unloading requirements, eliminating the need for external sorting equipment.
Finally, the Skypod integrates packing directly into the picking process.
Operators pick directly into fulfillment containers, removing the need for downstream manual packing. This feature pairs well with right-size packaging systems, said Exotec. They can be integrated with the Skypod to enable picking into appropriately sized containers, significantly reducing last-mile delivery costs.
ASRS gets 50% faster
“I’m excited {about the release] because I think the Next Gen Skypod brings unique capabilities, it saves a lot of space, it saves a lot of additional cost and complexities,” Bellamy told Automated Warehouse. “We also drastically improve the baseline of what an ASRS should do. It’s 30% more dense and it’s 50% faster in terms of picking.”
“We just raised the standard to a whole new level,” he added. “You can have a real omnichannel warehouse where, if you need to mix both eaches and cases, you put everything in one space, you save on inventory, you save on space, and then you just balance, depending on your channel mix. It’s future-proof and super flexible.”
Over the past two years, Exotec has sold and deployed the Next Generation Skypod system globally in stealth mode. The company said it has secured over 20 supply chain projects worldwide totaling $400 million. Its customers include casual wear seller Oxford Industries, industrial supplier Grainger, and online retailer E.Leclerc.
“When designing the Next Generation Skypod, our goal was to create a solution that would set the industry standard of operational excellence and elegance for the next decade and beyond,” said Romain Moulin, co-founder and CEO of Exotec.
“We’re already seeing our customers reimagine their entire supply chain around the transformative capabilities of this innovation, from combining case and each picking operations to leveraging outbound sequencing to improve transportation costs,” he said. “Witnessing this level of impact has been incredibly rewarding.”
Exotec deployed at E.Leclerc SECLIN Drive
E.Leclerc SECLIN is using the Exotec Skypod system as the operational backend to its curbside delivery service called “Drive”. This is an e-commerce grocery fulfillment service.
The Exotec Skypod system stores inventory in a high-density array and can quickly pull inventory for fulfillment of curbside customers, without the need for in-store item pickers to compete with customers. E.Leclerc SECLIN was an early pilot customer for testing the Next-Gen Skypod system.
Exotec plans to demonstrate its Next-Gen Skypod system at ProMAT 2025.
