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Accelerate fulfillment, maximize space and move towards lights-out operations

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AutoStore® is the world's leading goods-to-person solution for maximizing space and accelerating order fulfillment. The system combines intelligent software, AI-driven optimization, and modular automation to help businesses address labor constraints, limited space, changing SKU profiles, and growing fulfillment complexity.

Toyota Automated Logistics delivers AutoStore solutions that fit seamlessly with your operation, helping you move faster, smarter, and more reliably. Trusted by 150+ AutoStore customers worldwide, we have integrated 12,500+ robots, 10,200,000+ bins, and 3,000+ ports across a wide range of fulfillment operations.

Why Choose AutoStore?

Autonomy

Combining physical automation with AI-enabled software supports storage, replenishment, picking, inventory validation, case handling, and fulfillment workflows while reducing manual efforts.

Space Optimization

The modular grid design maximizes storage density, offering up to 4x more capacity compared to traditional shelving and up to 10-15% higher storage utilization with FlexBinsPort™.

High-Speed Fulfillment

Fast-moving robots and streamlined workflows enable thousands of picks per hour with near-constant uptime.

Scalability

Easily expand by adding robots, bins, workstations or even increasing the size of the grid without interrupting operations, supporting future growth and seasonal demand.

Operational Simplicity

Intuitive design and user-friendly software reduce training time, simplify maintenance, and minimize disruption during implementation.

Adaptability

Fits into complex layouts, low ceilings, freezers, and multi-level or multi-temperature environments, making it ideal for both greenfield and brownfield facilities.

How AutoStore Works

The AutoStore system consists of five main components: a structural grid, delivery robots, storage bins, operator workstations, and software. Its modular grid structure and fast-moving robots are designed to maximize space, accelerate inventory retrieval, adapt to seasonal demand and offer reliable performance even in cold storage environments. 

Autostore-system-model

 

1
GRID
The AutoStore grid is a modular aluminum framework that optimizes space up to four times more efficiently than traditional systems. It organizes inventory intelligently for faster, more accurate order fulfillment.
2
STORAGE BINS
Durable and flexible, AutoStore bins hold up to 30 kg (66 lbs) and come in three heights (220, 330, and 425 mm or 9", 13" and 17") with optional dividers for added versatility.
3
WORKSTATIONS
Operator ports where bins are delivered for picking, replenishment and other workflows. Multiple configurations ensure ergonomic design, task optimization, and layout flexibility.
4
ROBOTS
AutoStore robots navigate the grid to retrieve and deliver bins. Four models (R5, R5+, R5 Pro, R5+ Pro) support varying throughput needs and bin sizes.
5
SOFTWARE
AutoStore’s AI-driven software optimizes robot activity, identifies operational issues, and provides actionable recommendations. TAL’s proprietary software enhances efficiency and uptime and also expands out-of-the-box capabilities for the overall system.

A Smarter Approach to Order Fulfillment

Warehouse worker using a touchscreen at a goods-to-person workstation for automated order fulfillment.

Customer expectations continue to rise as labor remains constrained, operations become more complex, and every automation investment faces greater scrutiny. Toyota Automated Logistics helps customers address these challenges by integrating AutoStore into a solution that improves performance today while creating a practical path toward end-to-end lights-out operations.

  • AutoStore has more than 1,950+ live installations worldwide
  • Thousands of picks per hour with near-constant uptime (99.8%+), depending on configuration
  • Optimizes space up to four times more efficiently than traditional systems
  • Proprietary software orchestrates all robot traffic, optimizes picking sequences, and enables troubleshooting of errors in real time

TAL engineers and deploys AutoStore as a standalone solution or part of a broader system, matched to your operational requirements. The system can be designed to fit into complex layouts and multi-level or multi-temperature environments. It performs in both greenfield builds and brownfield retrofits, and it operates reliably in cold storage conditions.

Integration Capabilities

Toyota Automated Logistics doesn’t just install AutoStore. We engineer AutoStore to function as part of a larger fulfillment ecosystem to drive throughput, speed, reliability, and long-term growth. We can seamlessly integrate AutoStore with additional automation technologies like conveyors, pick-to-light, and robotic picking for a fully optimized fulfillment solution. 

This results in a fully optimized workflow from receiving through shipping, where every component in your operation works cohesively, reducing manual handoffs, and increasing overall throughput without adding labor.

 

  • Conveyor & Sortation Integration: Connects packing, sortation, and shipping workflows for continuous product flow and automated order routing.
  • Pick-to-Light Systems: Guides operators visually at workstations to increase pick accuracy and speed.
  • Robotic Picking: Pairs with robotic arms to automate repetitive item handling at the workstation level.
  • Warehouse Software Integration: Connect WMS, WES, ERP, and fulfillment software systems.
  • Cold Storage Compatibility: Operates in temperature-controlled environments for food, beverage, and pharmaceutical applications.
  • Right-Sized Packaging Equipment: Connects AutoStore to automated packaging solutions to create custom-fit cartons.
  • AGVs/AMRs Integration: Links AutoStore with autonomous mobile robots and automated guided vehicles to streamline material transport.

Key Considerations

Many facilities were not originally designed for automation. Structural constraints, such as columns, low ceilings, irregular layouts, and limited floor space, can make conventional AS/RS solutions impractical.

The AutoStore grid can be built around structural obstacles, installed under low overhead clearances, and configured to fit nearly any building layout, even bridging between buildings, expansions, or floors when needed.

This flexibility coupled with Toyota Automated Logistics expertise makes the AutoStore system a strong fit for legacy distribution centers and compact micro-fulfillment sites in addition to new greenfield facilities.

  • Facility Size and Layout: Footprint, ceiling height, slab thickness, and obstacles
  • Infrastructure Modifications: Flooring reinforcement, utility adjustments, layout changes
  • Product Characteristics: SKU size, weight, and handling requirements
  • Order Volume and Throughput: Daily orders, peak demand, picking speed
  • Seasonal and Micro-Fulfillment Needs: Scalability for spikes and urban fulfillment
  • Multi-Temperature and Cold Storage: Chilled, frozen, and ambient zones
  • Future Growth: AutoStore's modular design supports long-term expansion

Frequently Asked Questions

What is AutoStore?

AutoStore is the world's leading goods-to-person automated storage and retrieval system. It uses a modular aluminum grid, delivery robots, storage bins, and operator workstations to maximize storage density. The system delivers inventory directly to operators, eliminating manual travel through warehouse aisles.

How does AutoStore differ from traditional shelving and conventional AS/RS?

AutoStore maintains bins in a dense vertical grid, eliminating the wide aisles and storage gaps that traditional shelving and many conventional AS/RS systems require. This design delivers increased storage capacity in the same footprint. Unlike large-scale crane-based systems, the solution fits into existing facilities without major structural modifications. Its modular grid also allows incremental expansion without production downtime.

What industries or applications is AutoStore designed for?

The system serves a wide range of industries including e-commerce, retail, third-party logistics, pharmaceuticals, automotive, apparel, and food and beverage. It supports both high-volume fulfillment centers and smaller urban micro-fulfillment sites. It also operates in cold storage and mixed temperature environments, making it suitable for temperature-sensitive products. TAL engineers each installation to match the specific demands of the application.

What is the process of designing an AutoStore system?

Designing an AutoStore system involves assessing warehouse space, inventory types, and fulfillment goals. The grid is configured to maximize space and flow and integrate with existing software and automation.

How does TAL support implementation?

TAL engineers complete AutoStore solutions, from initial design and installation to integration and ongoing lifecycle support. The team evaluates facility footprint, ceiling height, slab thickness, SKU profiles, order volume, peak demand, seasonal needs, and future growth plans. TAL also integrates the system with conveyors, pick-to-light systems, robotic picking, and warehouse management software to deliver a fully connected fulfillment operation.

Can the system be expanded after initial installation?

Yes. The modular design allows you to add robots, bins, or workstations to the existing grid at any time without interrupting live operations. Additionally, the grid can be expanded as needed, even across multiple buildings or floors. This incremental scalability protects your original investment and lets you grow system capacity in step with business demand.

What AutoStore workstation (port) options are available?

AutoStore offers several workstation (port) configurations designed to support different throughput requirements, workflows, and facility layouts.

  • CarouselPort™ provides high-throughput picking and replenishment from a compact footprint.
  • ConveyorPort™ integrates with conveyors and downstream automation to support continuous product flow.
  • FusionPort™ combines ergonomic operation with flexible layout options for picking and replenishment activities.
  • RelayPort™ is designed for efficient replenishment workflows and can help separate inbound and outbound tasks.
  • FlexBinsPort™ dynamically handles all three standard bin heights from a single port, helping operations manage changing SKU profiles while reducing workstation complexity.
  • Toyota Automated Logistics helps determine the right Port configuration based on your throughput requirements, SKU profile, labor strategy, and overall fulfillment workflow.

What is Pio, and how does it relate to AutoStore?

Pio is an ultra-compact, plug-and-play AutoStore solution designed for rapidly growing organizations whose manual processes can no longer support future growth. This stand-alone system efficiently stores, retrieves, and picks items for online, in-store, or backroom fulfillment. With two picking workstations and an intuitive app, operators can be trained in minutes. The app also connects with popular shipping platforms to simplify ecommerce order processing. Contact our team to learn more.

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