Balluff and Kardex to deliver AutoStore ASRS system within 6 months

summary

October 10, 2025 – Balluff, Inc. sought to optimize storage and picking throughput at its Kentucky facility. Building on a history of successful collaboration, Balluff partnered with Kardex to deploy a customized AutoStore solution designed to meet both current operational demands and future growth in the Americas region.

Kardex took the project from award to commissioning in just six months, completing the project on time and within budget. Transformational results were achieved with minimal disruption and no major facility upgrades were required. The resulting system introduced multiple industry-first features to optimize space efficiency and processing speed, increasing throughput by 177%.

customers and tasks

Founded in Germany in 1921, Balluff, Inc. is one of the world’s leading manufacturers of sensor, identification, networking, and software solutions, specializing in high-quality smart industrial automation solutions. We are present in 68 countries and have more than 3,600 employees worldwide.

The company was looking to optimize storage and picking throughput at its Florence, Kentucky, facility and turned to Kardex as an ASRS to enhance its inventory storage and retrieval processes.

solution

Balluff thoroughly evaluated available warehouse automation technologies and selected AutoStore because it matched the company’s current needs and global localization strategy. Kardex provides the technical expertise and proven partnership to meet Balluff’s unique installation requirements and has already installed an AutoStore system at a Balluff facility in Hungary.

This groundbreaking project, consisting of an AutoStore Grid with 20,110 bins, seven robots, one ConveyorPort, and three CarouselPorts, went live within six months of contract signing. This was strategically planned to minimize disruption to ongoing operations and maximize space utilization within the existing infrastructure.

The unique two-step implementation process did not include a greenfield installation and included several industry firsts:

For the first time, an AutoStore was installed on one side of a wall and a carousel port on the other (cross-building installation) For the first time, seismic bracers were used instead of seismic columns, saving valuable floor space For the first time, the AutoStore service grid was extended to office areas rather than bridges or platforms, creating a more integrated facility design

“Balluff’s implementation of AutoStore was on time and on budget, and the Kardex team worked alongside Balluff from conception to project completion. Kardex has a dedicated team that continually delivers on its promises, and we plan to work with Kardex on future projects,” said Steve Duncan, Quality Assurance and Lean Manager, Balluff, Inc.

on schedule and within budget

Balluff’s project was completed on time and on budget, from contract signing to commissioning in just six months. This was achieved with minimal disruption to Balluff’s existing operations, as the solution was designed around the company’s existing facilities, making maximum use of existing infrastructure and requiring no major upgrades to buildings or power infrastructure.

Rapid transformation of fulfillment capabilities

Powered by Kardex, the AutoStore system is delivering significant productivity gains and overall efficiency gains in Balluff’s storage and fulfillment operations, including 177% more lines per hour compared to the previous carousel system. In addition to faster throughput, the new future-proof system has no bottlenecks and the AutoStore system’s compact design significantly increases storage density. It is scalable as Balluff’s future needs grow, making it easy to add new ports and robots as demand grows.

Workforce optimization and positive employee feedback

The new system has optimized Balluff’s workforce and increased overall operational efficiency. Feedback from Balluff employees has been overwhelmingly positive, with many reporting that it is easy to use, reliable, and efficient. The intuitive interface simplifies training and daily tasks, and the ergonomic design improves the working environment for warehouse staff. The ease of use and reliability of the system contributes to increased employee satisfaction and operational reliability.

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