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177% Faster Throughput |
6-Month Timeline |
Zero Facility Renovations |
| Balluff, Inc. has seen a dramatic increase in lines/hour | From contract signing to go-live took just six months | Thanks to creative design strategies and phased implementation |
Case at a Glance
Balluff, Inc. aimed to optimize put-away and picking throughput at its Kentucky facility.
Building on a successful history of collaboration, Balluff partnered with Kardex to deploy a customized AutoStore solution designed to meet both current operational demands and future growth for the Americas region.
Kardex was able to take the project from contract signing to go-live in just 6 months, coming in on time and under budget. It required no major facility upgrades – achieving transformational results with minimal disruption. The resulting system introduced multiple industry firsts to optimize space efficiency and process speed, delivering a 177% increase in throughput.
Balluff's Journey with AutoStore empowered by Kardex
Customer and Task
Founded in Germany in 1921, Balluff, Inc. is a leading global manufacturer of sensor, identification, network and software solutions, specializing in high-quality, smart industrial automation solutions. It has a presence in 68 countries and over 3,600 employees worldwide.
The company was looking to optimize put-away and picking throughput at its facility in Florence, Kentucky, and turned to Kardex for an ASRS to enhance its inventory storage and retrieval process.
The Solution
Kardex delivered the AutoStore grid with 20,110 bins, 7 robots, 1 ConveyorPort, 3 CarouselPorts, and a seamless integration with SAP in just six months from contract signing to go-live. It was strategically planned to minimize disruption to ongoing operations and maximize space utilization within the existing infrastructure.
"At AutoStore, our mission is to help companies move faster and scale smarter. The Balluff project with Kardex shows exactly what our technology is built for – rapid deployment, high throughput, and future-ready scalability without disruption. By combining AutoStore’s proven robotics with Kardex’s software and integration expertise, Balluff has unlocked a system that not only delivers immediate performance
gains but also provides a foundation for long-term growth. This is what we mean when we say AutoStore is moving things forward."
Mike Dickson
President of the Americas, AutoStore
Through a 2-phased approach, Kardex delivered multiple industry firsts:
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Through a two-phased approach, Kardex delivered multiple industry firsts. This marked the first time an AutoStore system has been installed on one side of a wall with CarouselPorts positioned on the other, enabling a true cross-building installation.
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It was also the first use of seismic bracers in place of seismic columns which preserved valuable floor space, and the first time the AutoStore service grid has been extended into an office area rather than relying on a bridge or platform, resulting in a more integrated facility design.
"The AutoStore implementation at Balluff was on time and under budget, with the Kardex team in parallel stride with Balluff from conception to project completion. Kardex is composed of a professional team who continually deliver on their promises, and we plan to work with kardex regarding future projects."
Steve Duncan
Balluff, Inc. Quality Assurance and Lean Manager
On-Time and Under Budget
The project at Balluff, from contract signing to go-live, took just 6 months to complete, coming in on-time and under budget. This was achieved with minimal disruption to Balluff’s existing operations as the solution was designed around the company’s existing facility, maximizing the use of existing infrastructure and requiring no major upgrades to buildings or power infrastructure.
Rapid Transformation of Fulfillment Capabilities
The AutoStore system empowered by Kardex is delivering dramatically improved productivity and greater overall efficiency in Balluff’s storage and fulfillment operations, including a 177% improvement in lines/hour compared with the previous carousel system. In addition to faster throughput, the future-proof new system has no bottlenecks and has significantly increased storage density due to the compact design of the AutoStore system. It is scalable to meet Balluff’s growing future needs, with new ports and robots easily added to meet rising demand.
Workforce Optimization and Positive Employee Feedback
The new system has optimized Balluff’s workforce and enhanced overall operational effectiveness. Feedback from the Balluff workforce has been overwhelmingly positive, with many reporting that it is user-friendly, reliable and efficient. The intuitive interface has made training and daily operation straightforward, and the ergonomic design has improved the working environment for warehouse staff. The ease of use and reliability of the system have contributed to improved employee satisfaction and operational confidence.
Lessons from Balluff's Journey with Kardex
Balluff’s automation journey with Kardex highlights what’s possible when reliability, innovation, and long-term planning come together. Their experience offers several practical takeaways for manufacturers and distributors evaluating automation or planning a system expansion:
Provider Reliability: Kardex has a proven track record and a professional team that works closely with customers to provide their best solution and support them in their automation journey.
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Innovative Customization: Kardex’s willingness to implement industry-first solutions demonstrates automation systems can be adapted to fit unique facility constraints.
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Strategic Phasing: Breaking complex implementations into planned phases can minimize operational disruption.
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Global Standardization: Implementing consistent automation solutions across global locations (as Balluff has done in Hungary and the US) creates operational synergies and simplifies employee training.
