Balluff Inc. needed to replace aging carousel technology and meet increasing fulfillment demands. The company signed a contract with Kardex Holding AG, and it deployed a fully operational AutoStore system in just six months without having to do any major infrastructure upgrades or operational downtime to install the system.
“We needed a fast, future-ready solution — and Kardex delivered,” said Steve Duncan, quality assurance and lean manager at Balluff. “Kardex was in lockstep with us throughout, and their professionalism and innovation exceeded expectations.”
Balluff sought a system that could meet today’s operational challenges and scale for tomorrow’s growth. The answer came in the form of a tailored AutoStore automated storage and retrieval system (ASRS) powered by Kardex. The ASRS was deployed at Balluff’s existing facility in Florence, Ky.
Founded in Germany in 1921, Balluff is a leading global manufacturer of sensor, identification, network, and software systems. It specializes in high-quality smart industrial automation solutions. The company has a presence in 68 countries and more than 3,600 employees worldwide.
Kardex deploys AutoStore system on time
Balluff and Kardex said they 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, seven AutoStore Red Line Robots, one conveyor port, and three carousel ports, fully integrated with Balluff’s SAP system.
In addition, the installation required no major facility renovations, thanks to creative design strategies and a phased implementation plan that maintained business continuity from Day 1, Kardex said.
The system featured elements that maximized both time and space, including:
- Cross-building system design, with the ASRS 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
“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,” said Duncan. “Kardex is composed of a professional team who continually deliver on their promises, and we plan to work with Kardex regarding future projects
Balluff improves throughput and storage capacity
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 reported 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.”
Kardex, a global AutoStore partner, supplies ASRS, integrated material handling systems, small-parts storage systems, and automated high-bay warehouses.
Earlier this year, Kardex launched the Kardex SnapVac, a semi-automated cleaning robot designed specifically for AutoStore Red Line systems. The company said it engineered SnapVac to eliminate dust and debris buildup from the top of the AutoStore grid without interrupting operations.
Kardex said SnapVac can help operators reduce downtime, extend robot lifespan, and ensure clean, safe, and high-performing systems.