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WHAT IS a lights-out warehouse?
A „lights-out warehouse“ is a fully automated warehouse that requires little to no human presence on the shop floor, allowing operations to run without lighting or staff onsite. Because of this, it is sometimes also referred to as a „dark warehouse“.
These warehouses rely on advanced automation – such as conveyors, sorters, pouch systems, and robotic picking – to manage storage, retrieval, sorting etc. for order fulfilment.
Also known as:
- Dark warehouse
- Autonomous warehouse
RELATED: Dark Warehouses to grab the spotlight in 2024
HOW DOES a lights-out warehouse WORK?
Lights-out warehouses combine completely automated material handling equipment with advanced control software such as Warehouse Management Systems (WMS) and/or Warehouse Control Systems (WCS).
Key features of a dark warehouse include:
- Automated storage – ASRS, shuttle systems, and robotics manage inventory.
- Automated transport – conveyors, sorters, and pouch systems move goods across the facility.
- Automated picking – robotic or goods-to-person systems handle order selection.
- Software integration – WMS and WCS synchronise data with automation to optimise flows.
- Predictive analytics – AI-driven insights anticipate demand, faults, and maintenance needs.
BENEFITS OF a lights-out warehouse
- Efficiency: Lights-out warehouses operate 24/7 without interruption.
- Accuracy: Reduces picking and handling errors.
- Labour optimisation: Minimises reliance on human labour in high-cost or labour-scarce markets.
- Energy savings: Requires little or no lighting and can optimise HVAC use.
- Safety: Removes people from potentially hazardous environments.
- Scalability: Handles high throughput and seasonal peaks.
LIGHTS-OUT WAREHOUSE VS TRADITIONAL WAREHOUSE
| Feature | Lights-out warehouse | Traditional warehouse |
|---|---|---|
| Workforce | Minimal human presence | Labour-intensive |
| Lighting | Little or no lighting required | Fully lit for human operators |
| Processes | Automated storage, picking, transport | Manual or semi-automated processes |
| Operating hours | 24/7 possible | Limited by shift schedules |
| Accuracy | High due to automation | Prone to human error |
HOW BEUMER GROUP SUPPORTS lights-out warehouses
While BEUMER Group does not supply all the automation elements directly, we act as a trusted integrator, connecting warehouse management systems with automation technologies to enable lights-out warehouse operations.
Our technologies play a central role in making dark warehouses a reality:
- BG Pouch System – handles dynamic picking, sequencing, and order consolidation in fully automated environments.
- Automated line and loop sortation systems – route goods with high accuracy across complex flows.
- Conveyor systems – ensure continuous, reliable movement of items throughout the facility.
- Integration with WMS and WCS – synchronises data, control, and automation for seamless dark warehouse performance.
FAQ ABOUT lights-out warehouses
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It’s called a lights-out warehouse because human workers are not needed for most operations, the facility can run without lighting – relying solely on automation.
