Fully Automated Warehouse Solutions: Performance, Control and Scalable Growth

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What is a fully automated warehouse?

Stacker Crane Automated Retrieval System

A fully automated warehouse is a facility where the majority of storage, movement and handling activities are carried out by automated systems rather than manual processes. From inbound goods through to storage, retrieval and despatch, automation is designed to control how inventory flows through the operation with minimal human intervention.

Unlike partially automated environments, a fully automated warehouse operates as a connected, end-to-end system, delivering predictable performance, consistency and long-term scalability.

When designed correctly, full automation doesn’t just improve efficiency it fundamentally changes how a warehouse performs today and how it grows in the future.

What is a fully automated warehouse system?

A fully automated warehouse system combines physical automation with intelligent software to manage the complete operation.

This typically includes:

Automated storage and retrieval systems (AS/RS)
Conveyor and sortation systems
Robotics and automated handling equipment
Warehouse control systems (WCS) and integrations
Optimised layouts designed for flow, space and expansion

The key difference between automation and effective automation is integration. Each element must work together as a single operation rather than as standalone technologies.

This is why system design, coordination and accountability are critical to success.

When does full warehouse automation make sense?

Fully automated warehouse solutions are not right for every operation, and committing too early can introduce unnecessary cost and risk.

They are best suited to warehouses with:

High, consistent volumes
Repeatable and predictable processes
Long-term growth or capacity constraints
A requirement for reliability, accuracy and control
Rising labour costs or availability challenges

Oakway works closely with customers to determine whether full automation is the right strategic step, ensuring investment is aligned with operational reality, risk and commercial return, not just technical ambition.

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Designing a fully automated warehouse around the entire operation

A fully automated warehouse only performs well when every element of the operation is considered.

Rather than starting with technology, Oakway designs automation around the entire warehouse ecosystem, including:

Physical layout and site constraints
Storage strategy and inventory profiles
Goods flow, sequencing and throughput requirements
People, supervision and exception handling
Future expansion and scalability

By taking a holistic view, automated warehouse systems integrate seamlessly into day-to-day operations, delivering controlled, resilient and future-ready performance.

What fully automated warehouse solutions deliver

When applied in the right environment, fully automated warehouse solutions can deliver measurable operational outcomes, including:

Increased throughput and consistent performance
Reduced dependency on manual handling and labour
Improved accuracy, reliability and order quality
Better use of available floor space and cubic capacity
Scalable performance as demand grows

The focus is always on outcomes, not technology for its own sake.

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Managing complexity and risk in fully automated warehouses

Fully automated warehouse projects carry inherent complexity and risk if not managed correctly.

Oakway takes a practical, phased approach to automation, ensuring systems are:

Correctly specified and coordinated
Integrated and tested as a complete operation
Commissioned with clarity and control
Adopted smoothly by operational teams

By planning for commissioning, adoption and long-term operation from the outset, disruption is reduced and return on investment is protected.

One partner. End-to-end accountability.

Fully automated warehouses require clear ownership across design, integration and delivery.

Oakway acts as a single, accountable partner, coordinating all elements of the automated warehouse system. This removes fragmentation, simplifies decision-making and ensures automation performs as intended.

We don’t just deliver systems.
We deliver working, fully automated warehouse environments.

Assessing feasibility before committing to full automation

One of the most common mistakes organisations make is committing to a fully automated warehouse before fully understanding operational readiness.

Oakway supports businesses at the assessment stage, helping decision-makers understand:

Whether full automation is appropriate
What level of automation delivers the best return
Where risks exist within layout, flow or demand
How systems should scale over time

This ensures automation decisions are based on evidence, not assumption.

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The extra warehouse capacity enables us to continue to offer expansive choice and unrivalled customer service. It was simple to work with Oakway Storage, from initial conversations right through to installation everything happened when expected with the minimum of interruption to business.

Ross Duncanson – Director, E. Tupling

Oakway have been brilliant in supporting our business with a flexible cask racking solution that has supported our business through a period of rapid growth

Jan Damen – General Manager, The Single Cask

From quote to installation, Oakway Storage provided attention to detail that made them stand out against all other suppliers. The personal touch coupled with their keenness to get on site really made the decision to work with Oakway a simple one.

David Hunter – Supply Chain Project Manager, Bergen Logistics

During the last 3 months, since taking the lease of a 103,000 sq.ft. site in Chester, we have been working with Oakway Storage who have designed, supplied and installed approximately 13,000 pallet positions of Apex pallet racking in a VNA configuration to a height of around 11.5m. We are delighted at the professionalism and dedication of our sales and design contact and the efficiency of the installation crew and would not hesitate to recommend them for similar projects.

Peter Gates – Managing Director, PW Gates

In partnering with Oakway Storage, our transformation went beyond a project; it became a collaborative journey. Facing the challenge of an empty warehouse, Oakway's pragmatic and thoughtful planning stood out. Their seamless coordination, from mezzanine installation to the developing glass laboratory space, showcased expertise and a true partnership. The future-ready flexibility ensures adaptability as we grow, emphasising a strategic approach that fosters innovation and sets the stage for sustained success.

Dominic Nott – Director, March May Ltd

I like the family business feel to the company and how flexible the consultation phases have been each time. Top company!

Will Jansen – Chief Operating Officer, Human Forest

Working with Oakway Storage on the repurposing of elements of our warehouse has been a very straightforward experience. The Oakway team supported us throughout and made the project to improve our shelving and racking easy to achieve. I’d recommend them to any business looking to undertake a similar project.

Duane Luke – Production Coordinator, STS Ltd

It's been a pleasure working with Oakway. They designed a system that suited our budget and timescales, delivering a turn-key solution that met all our needs.

Stuart McMillan – Operations Manager, Auld Bond Bottlers

Great execution of the project from end-to-end. We run a very busy 3PL warehouse and were delighted the the Oakway Storage team were able to work around us. From the first project scope visits to the VNA racking install the team were professional, polite and knowledgeable. Thanks guys!

Andrew Fell – Site Manager, Dependall

FAQs about fully automated warehouses

Q) What is the difference between a fully automated warehouse and a semi-automated warehouse?A fully automated warehouse relies on automated systems for most storage, movement and handling activities, with minimal manual intervention. A semi-automated warehouse uses automation in specific areas but still depends heavily on manual processes elsewhere. Fully automated warehouse systems are typically used where throughput, consistency and long-term scalability are critical.

Q) How much does a fully automated warehouse cost?

The cost of a fully automated warehouse varies depending on size, system complexity and throughput requirements. Investment is typically offset by long-term operational savings, improved performance and reduced reliance on labour.

A feasibility-led approach is essential to ensure automation delivers a clear return on investment.

Q) Is a fully automated warehouse suitable for small or growing businesses?

Fully automated warehouse solutions are generally best suited to operations with stable volumes, repeatable processes and clear growth forecasts. Smaller or rapidly changing businesses may benefit more from phased or partial automation.

Q) What technologies are used in a fully automated warehouse system?

A fully automated warehouse system may include AS/RS, conveyors, robotics, sortation systems, warehouse control software and integrated material handling equipment.

Effectiveness depends on how well these technologies are designed and integrated as a single operation.

Q) What are the main benefits of a fully automated warehouse?

Benefits include increased throughput, improved accuracy, reduced manual handling, better space utilisation and scalable performance. The greatest gains are achieved when automation is aligned with operational outcomes.

Q) What are the risks of fully automated warehouse projects?

Risks include poor integration, lack of adoption, underestimating complexity and misalignment with demand. These risks can be reduced through careful planning, phased delivery and clear end-to-end accountability.

Q) How long does it take to implement a fully automated warehouse?

Timelines vary based on scope and complexity. Most projects include design, integration, installation, commissioning and operational ramp-up phases.

Planning for long-term operation helps ensure a smooth transition.

Q) How do I know if full automation is right for my warehouse?

Full automation works best where volumes are consistent, processes are repeatable and long-term growth is planned. A structured assessment helps determine whether full automation or an alternative approach is the right strategic choice.

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