Warehouse Automation Market Size, Share, Growth, and Industry Analysis, By Type (Goods-To-Person Technologies (GTP), Pick-To-Light Systems, Sortation Systems, Collaborative Mobile Robots, Other), By Application (Energy, Transport/Logistics, Healthcare, Retail, Manufacturing, Other), and Regional Forecast to 2035

•   
•   
  

  Request a Free sample to learn more about this report

    

WAREHOUSE AUTOMATION MARKET OVERVIEW

The global Warehouse Automation Market size is USD 33.06 billion in 2025, is expected to rise to USD 36.43 billion in 2026, and is forecasted to reach USD 97.15 billion by 2035, expanding at a CAGR of 10.2% throughout the period 2025-2035.

This is affirming the current upward trend in the Warehouse Automation market since most companies need to minimize their operation costs and time in a bid to boost on their supply chain techniques. Warehouse automation is the implementation of various systems like robotic systems, ASRS, conveyors and AMRs to deal with issues like inventory control and management, order collection and sorting. This has been as a result of growing consumers’ expectations for shorter delivery time, effective stock control, and integration of Industry 4.0 solutions. Four business segments are mainly investing in warehouse automation: the retail business, the e-commerce segment, and manufacturers, who aim at minimizing errors, effective space management and low expenses. As organizations expand capacity to feed the world requirement, the necessity for robotic systems in warehouses likewise progresses. Using features of Artificial Intelligence, Machine Learning, and IoT, warehouse automation provides a competitive advantage necessary integrating it into a modern Supply Chain Management strategy.

KEY FINDINGS

COVID-19 IMPACT

Warehouse Automation market Had a Negative Effect Due to Disruption in Supply Chain and Consumer Demand during COVID-19 Pandemic

The global COVID-19 pandemic has been unprecedented and staggering, with the market experiencing lower-than-anticipated demand across all regions compared to pre-pandemic levels. The sudden market growth reflected by the rise in CAGR is attributable to the market’s growth and demand returning to pre-pandemic levels.

The effect of the COVID-19 pandemic has been both positive and negative towards the Warehouse Automation market share; where the initial negative impacts came from disruptions of global supply chain and manufacturing. COVID restrictions hindered the construction of automation machinery and brought in more project interruptions and freezes. Also, lack of capital funding in many companies threatened the financial basis essential to invest or upgrade on new automatic systems. Nevertheless, since the demands for electric commerce raised during the pandemic and the supply chains experienced emissions, the topic of warehouse solutions emerged and partially levelled the situation. Even after the pandemic, the numbers have shown that adoption of warehouse automation remain high However, the COVID-19 pandemic exposed weaknesses in global logistics and proved that automation remains an essential factor to maintain and guarantee the flow in supply chains.

LATEST TRENDS

Integration of Artificial Intelligence and Machine Learning in Warehouse Automation Systems to Drive Market Growth

In the present generation, the most advanced trend that has implemented the Warehouse Automation market is the use of Artificial Intelligence (AI) and Machine Learning (ML) solutions for improved performance and decision-making. AI use in the warehouses allows them to predict changes in demand, to keep track of inventory and to optimize order fulfilment by analyzing data. When it comes to the operation of machines, real-time data can be processed using machine learning algorithms and the processes executed in such ways as will reduce time wastage. Smart systems are useful in these areas due to their ability to address large and difficult problems including prediction and scheduling of maintenance of intelligent industrial devices, path planning for Mobile Robots, and tracking of inventory levels in real-time respectively. AI and ML technologies are proving useful in transforming the warehouses into smart environment where operations are automated and businesses stand to gain flexibility, speed and accuracy all of which translate to cost reduction and better customer satisfaction.

• According to the International Federation of Robotics (IFR), over 2.7 million industrial robots were in use worldwide as of 2020, with significant growth in the logistics and warehousing sectors. The integration of robots, such as Automated Guided Vehicles (AGVs) and Automated Storage and Retrieval Systems (ASRS), is becoming increasingly common in warehouses, driven by the need for faster, more efficient operations.

• As per the World Economic Forum (WEF), around 45% of warehouses globally are expected to integrate Internet of Things (IoT) devices by 2025. These IoT-enabled devices provide real-time data analytics and tracking, which improve operational efficiency by optimizing inventory management and reducing downtime.

•   
•   
  

  Request a Free sample to learn more about this report

    

WAREHOUSE AUTOMATION MARKET SEGMENTATION

By Type

Based on Type, the global market can be categorized into Goods-To-Person Technologies (GTP), Pick-To-Light Systems, Sortation Systems, Collaborative Mobile Robots, Other

• Goods-To-Person Technologies (GTP): The GTP systems advance the overall process by taking the products to the worker for picking, which minimizes cycling time and enhances the order-picking rates. Such technologies are of most value where the demands are high, such as in e-commerce and retailing operating from warehouses.

• Pick-To-Light Systems: This system employs lights to direct the operator to the position of the right item for pick up, hence reducing the time spent looking for the right item. This one is often implemented in the situations where the first and the foremost importance is placed on the rapid, yet highly effective order picking and order shipping, typical for such setting as retail distribution centers.

• Sortation Systems: Sortation systems provide mechanized way of sorting various goods according to prescribed factors including delivery location or order category in enhancing goods flow within a warehouse. Such systems are implemented in large scale warehouses for easy processing and distribution of products.

• Collaborative Mobile Robots: These are used in collaboration with human operators to move freight within the warehouse to optimize on output and minimize on inward physical exertion. They are most valuable in such situations where the tasks, and corresponding routes, have to be continually reassessed.

• Other: This includes all other warehouse automation systems that are mostly used across the warehouse, for example the automated guided vehicles (AGVs) and the robotic arms used in handling, storing and moving product throughout the warehouse.

By Application

Based on application, the global market can be categorized into Energy, Transport/Logistics, Healthcare, Retail, Manufacturing, Other

• Energy: Enhanced energy productivity logistic technologies include energy efficient robotics and logistics equipment with the intended purpose of using less energy whilst delivering effective warehouse functionality.

• Transport/Logistics: Automation technologies within and outside warehousing transport the goods within and to other facilities more efficiently. This includes conveyors, sorting equipment and transport robots which major goal is to organize the movement of products.

• Healthcare: In the health sector, automation of the warehouse helps in achieving the right placement and retrieval of medical supplies and medicines and helps in making the right distribution with high accuracy and reasonable measures towards safety.

• Retail: Automating the retail warehouse is all about enhancing the rate and efficiency of order selection, picking, packing, and replenishment services that retailers have to provide to customers due to the heightened expectations of an e-commerce world.

• Manufacturing: In manufacturing warehouse automation systems enhance storage and rotation of raw materials and or finished products which makes lean manufacturing possible.

• Other: This category embraces industries outside the traditional domains where WA is used, food and beverage industries, aerospace, the automotive industry among others as they will benefit from the automation in inventory and distribution.

MARKET DYNAMICS

Market dynamics include driving and restraining factors, opportunities and challenges stating the market conditions.

Driving Factors

Increased Demand for Faster Order Fulfilment to Boost the Market

The most compelling factor towards the proliferation of Warehouse Automation market growth is the increasing pressure to rotate orders faster, caused by an ever-increasing e-commerce marketplace. From the ordering time to delivery time, buyers are also demanding more and shorter times such as the use of the 3-5 day or even one and half to three hours delivery time for light goods placed online. Sorting technology, robotic solutions, and automated storage and retrieval systems (ASRS) provide warehouse capability to process more orders with less time and fewer errors. These technologies shave the time required to undertake manual operations, simplify and expedite sorting and picking, as well as guarantee that products are processed optimally for dispatch. With the trend of e-commerce developing in the future, efficient and scalable warehouse automation systems become increasingly important, leading to the rapid development of this market.

• According to the U.S. Bureau of Labor Statistics (BLS), warehouse labor costs have increased by 18% over the last five years, prompting many companies to invest in automation to mitigate labor shortages. In 2021 alone, the warehousing and storage industry in the U.S. employed over 1.2 million workers, but companies are finding it difficult to fill these positions, especially in the context of increasing demand for faster delivery services.

• As reported by the U.S. Census Bureau, e-commerce sales in the U.S. reached $870 billion in 2021, a 14% increase from the previous year. This surge in online shopping is creating an urgent need for automation solutions in warehouses to handle the increased volume of orders, reduce picking errors, and speed up delivery times. Automation technologies, such as robotic picking and sorting systems, are being integrated to meet this demand.

Labour Shortages and Rising Operational Costs to Expand the Market

The second imperative for the Warehouse Automation market is the lack of available and affordable human capital, coupled with the tendency towards increased costs in developed countries. As many warehouses are now failing to attract enough skilled employees and are forced to pay even more for wages and other labour-related costs, automation offers the economical way out in alleviating-pressure from human workers. Robotic solutions can complete tedious work better than certain individuals and are free from mistakes, making them work more than just 24 hours a day, and translate into substantial savings overtime. Furthermore, automation mitigates the problems arising from a lack of workforce, among industries that include e-commerce, retails stores, and manufacturing businesses that rely on large distribution warehouses. Since labour costs are increasing, companies are using automation in an attempt to remain relevant and work more effectively.

Restraining Factor

High Initial Investment and Maintenance Costs Impede Market Growth

One of the most important limitations to the Warehouse Automation market is the relatively high initial and operational costs of automation. Acquisition cost of raw materials and installation of automations including robotic systems, Automated Storage and Retrieval Systems (ASRS), connectors and conveyors among others can be extremely high. In fact for small and medium enterprises, these costs may be too expensive to incur. Also, the continuing costs associated with these systems include the acquisition of software upgrades, technical support and staff training. The long-term cost savings of automation are overshadowed by the up-front capital expenses and the continuous operational costs that may deter rate of adoption particularly among firms facing the constraints of limited financial supply or firms operating in industries characterised by low margins.

• According to the International Society of Automation (ISA), the high upfront cost of automation systems remains a key barrier. The average cost of setting up a fully automated warehouse can range from $1 million to $20 million depending on the size of the warehouse and complexity of the system. Many small to mid-sized businesses struggle to justify these costs, limiting the pace of automation adoption.

• As highlighted by the European Automation and Robotics Association (EARA), integrating automation systems into existing warehouse operations can be challenging, especially for legacy warehouses. Many facilities face technical difficulties when incorporating automated systems like AGVs or ASRS into their current infrastructure. Approximately 30% of warehouses globally report integration issues with new technologies.

Growth in E-Commerce and Omnichannel Retailing to Create Opportunity for the Product in the Market

Opportunity

One opportunity that is very promising in the Warehouse Automation market is inspired by the meteoric rise of e-commerce and omnichannel selling. Never before has the need for quick and accurate order fulfilment so paramount, causing retailers and logistics providers to incorporate Automated Systems. Automated solutions in the context of warehouses help organizations adjust to the trend of ramped up delivery time’s consumers now expect while keeping operational costs in check. Automation can assist companies become more versatile when dealing with a growing number of orders as well as enhance stock and supply chain methodologies enabling a competitive edge within the context of rapid fashion retail..

• According to the Food and Agriculture Organization (FAO), global cold chain logistics is expanding rapidly, driven by the increasing demand for temperature-sensitive products like food and pharmaceuticals. Automation technologies, such as robotic palletizing and cold storage management systems, are expected to play a significant role in optimizing cold chain operations, which is a growth opportunity in the warehouse automation market.

• As reported by the World Economic Forum (WEF), AI and machine learning are revolutionizing warehouse operations by enabling predictive analytics and enhancing decision-making processes. By 2025, over 60% of warehouses are expected to incorporate AI for demand forecasting, inventory management, and route optimization, offering significant opportunities for growth in automated warehouses.

Integration of Automation with Legacy Systems Could Be a Potential Challenge

Challenge

One big problem that companies experience in implementing warehouse automation is compatibility of new automated systems with old structures. Numerous modern warehouses use traditional classical approaches and new technologies that may be incompatible with the current automated systems. One notes that a lot of decisions are made this way which causes inefficiencies, delays and even incurring other costs during transition. Overcoming of this challenge involve analyzing the situation and allocating resources for compatible technologies as well as training the staff on how to operate new systems.

• According to the World Economic Forum (WEF), while automation reduces the reliance on manual labor for everyday tasks, there is a shortage of skilled labor required for system maintenance and troubleshooting. By 2023, it is expected that 30% of warehouse automation systems will be underutilized due to a lack of qualified technicians to manage them.

• The U.S. Department of Homeland Security (DHS) has identified cybersecurity as a significant risk for automated warehouses. With the increasing integration of IoT devices and AI systems, the number of potential entry points for cyberattacks also increases. In 2022, more than 15% of companies in the logistics sector reported data breaches related to their automation systems, highlighting the need for enhanced security measures.

•   
•   
  Request a Free sample to learn more about this report

    

WAREHOUSE AUTOMATION MARKET REGIONAL INSIGHTS

• North America

North America region hold highest market share for Warehouse Automation systems due to its higher adoption level with respect to advanced Automation solutions and increasing trend of e-Commerce industries. Depending on the type of goods, the most advanced solutions like robotic systems, AMRs, and AGVs applied in the U.S. Warehouse Automation market. There has been a growing trend in the implementation of warehouse automation in the North American countries to sorted efficiency gains, to respond to the growing demand for rapid deliveries and labour shortages. Given that innovation remains a principal strategy of the region’s supply chain, accompanied by proper infrastructure, the region is a significant contender in the warehouse automation demand market.

• Europe

The Warehouse Automation market is also expected to have substantial growth in Europe as consumer concern regarding sustainability and recording low operational cost continues to increase. It also noted that there is increased adoption of green automation technologies especially as a result of adopting energy efficient robotic systems and eco friendly packaging material. Due to high standards in environmental legislations and customer concern for sustainability, European companies’ goal is automation for minimizing avoidance, energy, and cost. Further, industries such as automotive, retail and logistics are integrating the concept of warehouse automation which is a key driver to the market growth throughout the continent.

• Asia

The Warehouse Automation market is expected to be led by Asia-Pacific over the foreseeable years because of the factors like city progressiveness, escalating human resource costs, and increase in e-commerce. Thus, China, India, Japan, and South Korea are investing most heavily in automation instruments, as companies are trying to address the growing challenges of supply change management. A compelling force for faster and accurate order fulfilment is the fast-growing e-commerce business in Asia. Computerization is preferred in competitive manufacturing industry of the region and thus more usage in warehouses of different sectors.

KEY INDUSTRY PLAYERS

Key Industry Players Shaping the Market through Innovation and Market Expansion

Key enterprise gamers in the Warehouse Automation market consist of Daifuku, Dematic, SSI Schaefer, Vanderlande International, KUKA AG, Honeywell Intelligrated and Swisslog, Murata Machinery, Toyota Industries Corporation. They are among the leading organizations when it comes to designing and implementing automated technologies including robotics, automated storage and retrieval systems (ASRS), conveyors as well as sorters. These goals revolve around optimally functioning warehouses, cutting costs that are incurred as well as supply chain management. These players are steadily mastering the new age technologies in Artificial Intelligence, machine learning, and robotics to determine the future and evolution of warehousing across industries, including e-commerce, retail, manufacturing, and logistics industries.

• Daifuku: Daifuku, a global leader in material handling systems, has provided automated solutions for various industries, including automotive, electronics, and food & beverage. According to the International Materials Handling Industry (IMHI), Daifuku's systems are installed in over 150 countries. In 2021, Daifuku was responsible for over 20% of the global market share in warehouse automation systems, with a focus on integrating robotic systems into warehouses.

• Dematic: Dematic, a leading automation solutions provider, serves major industries such as retail, food & beverage, and e-commerce. According to the Material Handling Industry (MHI), Dematic's solutions have been implemented in over 10,000 warehouses worldwide. In 2022, Dematic launched an AI-powered warehouse management system (WMS) that enhances inventory accuracy and operational efficiency.

List of Top Warehouse Automation Companies

• Daifuku (Japan)
• Dematic (U.S.)
• SSI Schaefer (Germany)
• Vanderlande (Netherlands)

KEY INDUSTRY DEVELOPMENTS

September 2024: Dematic introduced a new ASRS for the parcels at its Milton Keynes, UK site in September 2024 that comes with AI software for predictive maintenance. A new system is intended to provide improved processes and costs and lower time losses by using real-time data analytics to forecast equipment failures. With the ability to increase efficiency of accuracy and rate of fulfilling orders, it is best suited to online orders and distribution of goods.

REPORT COVERAGE

The market for Warehouse Automation is expected to have more growth going forward as client organisations are shifting their focus to enhance efficiency, shorter cycle time and low cost of operation. The need for automation systems is going up due to the progress in robotics, AI and IoT technologies in decision-making processes and managing of warehousing. The growth of the e-commerce industry coupled with scarcity of labour, and the business’s requirement to increase the speed and accuracy of supply chains foster technological advancement in the industry. To address these challenges companies are implementing automation solutions right from picking PODs to GMRs – Goods-To-Person. They include; high initial costs, retrofitting with existing systems make it difficult and yet automation is turning out to be an important part of updating various warehouses. This is because as industries adopt automation to remain relevant in the market, then the market is expected to grow significantly especially in the North America Europe and Asia-Pacific. In future, advancements in automation technologies will continue to enhance these processes and add substantial value to productivity and costs of most industries.