Pallet Shuttle System | High-Density Storage Solutions

Handling 10,000 orders in a traditional warehousemay require 50 workers pulling overnight shifts. In contrast, a warehouseautomation system can complete the same workload with just over a dozen staff —within regular office hours.

The difference isn’t manpower; it’s warehouseautomation.

With Hong Kong’s soaring land prices and risingoperating costs, traditional warehouse operations are struggling to keep upwith fast-moving e-commerce and supply chain demands.

So, what types of warehouse automation systems areavailable in Australia? And how can they solve real operational challenges?This guide breaks it down.

Common Warehouse Automation Systems in Australia

To improve efficiency and maximise ROI, businessesneed a clear understanding of how different warehouse automation solutions work,and where they deliver the most value.

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1. Conveyor Systems in Warehouse Automation

Conveyor systems are one of the most widely usedwarehouse automation solutions, designed for point-to-point and long-distancematerial handling.

In traditional warehouses, workers spendsignificant time walking and transporting goods. With conveyors, items moveautomatically between receiving, storage, picking and packing zones.

Modern automated conveyor systems integrate barcodescanning and weight detection to identify and remove sorting errors — improvingboth accuracy and throughput.

2. AMR Warehouse Robots & Vision-GuidedForklifts (AGF)

AMR warehouse robots (Autonomous Mobile Robots) andAGF (Automated Guided Forklifts) are rapidly transforming warehouse operationsin Hong Kong.

Unlike traditional AGVs that rely on fixed tracks,AMRs use real-time navigation and environmental sensing to move freely andavoid obstacles. This makes them ideal for dynamic warehouse environments.

AMRs enable a “goods-to-person” picking system,where robots deliver items directly to operators — reducing walking time andboosting productivity.

Meanwhile, AGF forklifts automate pallet transportand high-risk handling tasks. They improve warehouse safety while enabling 24/7automated operations, reducing reliance on manual labor.

3. AS/RS Australia: Automated Storage and RetrievalSystems

With limited land availability, AS/RS (AutomatedStorage and Retrieval Systems) in Hong Kong are essential for maximising space.

These systems use high-rise racking, shuttlesystems and stacker cranes to achieve high-density storage — often severaltimes greater than traditional warehouse setups.

Integrated with WMS and WCS, ASRS systems automateinventory storage and retrieval, reducing manual handling and improvingaccuracy.

For businesses managing large SKU volumes and highturnover rates, AS/RS is a critical warehouse automation investment.

4. Mezzanine Systems for Warehouse Space Optimisation

A warehouse mezzanine system creates additionalstorage levels within existing facilities, maximising vertical space withoutmajor structural changes.

This is especially useful in Hong Kong’s olderindustrial buildings. When combined with lifts or automation equipment,mezzanines can significantly increase storage capacity at a relatively lowcost.

By combining these warehouse automationtechnologies, businesses can overcome three key challenges in Hong Kong: highrent, labor shortages and operational inefficiencies.

Case Study: Warehouse Automation in Australia

A major e-commerce company operating a 40,000 sq.ft. warehouse in Kwai Chung faced rapid order growth, with peak volumesexceeding 10,000 orders per day.

Manual picking using paper lists led to frequenterrors, long working hours and high staff turnover — common challenges intraditional warehouse operations.

To improve efficiency, the company implemented acustom warehouse automation solution with BPS:

• Installed mezzanine racking to increase storage and picking     capacity
• Deployed AMR warehouse robots for a goods-to-person picking system
• Integrated automated conveyor systems for seamless packing and     dispatch

Results of Warehouse Automation Implementation

The transformation delivered measurable results:

• 99.9% picking accuracy
• 3× increase in order processing efficiency
• 40% reduction in labour requirements

Warehouse staff shifted from manual picking tosystem operation and quality control —improving both productivity and jobsatisfaction.

BPS Global Australia: Warehouse AutomationExperts in Australia

Successful warehouse automation in Australia requires more than just equipment, it demands expert planning, systemintegration and technology alignment.

BPS Global Australia provides end-to-endwarehouse automation solutions, including:

• Automation strategy and data analysis
• Equipment selection (AMR, AGF, AS/RS, conveyors)
• Mezzanine system design
• Full system integration (WMS/WCS)
• On-site implementation and support

Upgrade yourwarehouse with the right automation strategy.
Contact BPS Australia today to start your warehouse automation journey andstay ahead in Hong Kong’s competitive logistics landscape.

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Are your warehouse staff constantly walking back and forth every day, spending excessive time locating and picking items — yet still struggling to keep up with growing order volumes? The root issue often isn't manpower, but whether your picking model suits your business.

"Goods-to-Person" (GTP) refers to automated systems delivering items directly to a stationary picking workstation, while "Person-to-Goods" (PTG) requires workers to travel to storage locations to pick items. Let's break down these two approaches to help you determine which model can maximise your operational performance.

Person-to-Goods vs Goods-to-Person: A Comprehensive Comparison

With high rents and ongoing labour shortages in Hong Kong, choosing the right picking model has a major impact on operating costs.

A Goods-to-Person system replaces manual picking with automation, significantly improving efficiency while maximising limited warehouse space — making it especially suitable for growing businesses.

While Person-to-Goods has a lower entry barrier, increasing order volumes will gradually drive up labour and space costs, eroding profit margins.

Key Differences

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Technology Behind Goods-to-Person Systems

It's important to note that GTP is not a single piece of equipment, but a combination of automation solutions. Depending on warehouse size, SKU count, and order profiles, businesses can choose the most suitable setup:

• Grid-based Systems
  Robots transport entire shelves or pallets to picking stations. These systems require less rigid rack structures, are faster to deploy, and allow multiple related SKUs on the same shelf — improving picking efficiency.
• Shuttle Systems
  Extract individual totes and deliver them to workstations before returning them. With standardised structures, they support extremely high speed and throughput — ideal for high-frequency operations with relatively concentrated SKUs.
• Robotic GTP with Fixed Racks
  Robots retrieve totes from pre-designed fixed racking systems. These solutions maximise vertical space (up to 30 feet or more), making them ideal for high-SKU, high-density storage environments.
• Carousel Systems
  Use horizontal or vertical rotation to bring items to operators. They are ideal for space-constrained warehouses and help improve picking accuracy while reducing manual errors.

Each architecture has its strengths in space utilisation, speed, and investment cost. Businesses should choose based on their order structure, SKU characteristics and future scalability — not just the level of automation.

How to Choose the Right Model for Your Warehouse

Selecting the right picking model requires evaluating several factors:

• Daily Order Volume
  If you process a few hundred orders per day with limited growth, PTG may suffice. But if orders exceed 1,000 daily or are rapidly growing, GTP offers significant efficiency advantages.
• SKU Count and Product Characteristics
  The more SKUs and the smaller the items, the greater the benefit of GTP. Large or heavy items may require specialised automation solutions.
• Warehouse Size and Lease Terms
  With typical lease cycles of 2–3 years, companies must assess ROI timelines. If space is limited but storage needs are growing, GTP's dense storage is ideal.
• Seasonal Demand Fluctuations
  For businesses with peak seasons, GTP systems provide far greater scalability than relying on temporary labour.

Ultimately, beyond order volume and space, companies should also evaluate ROI, system integration costs, and operational disruption during implementation.

Real Case: How a Hong Kong E-commerce Brand Improved Efficiency

A local health supplement e-commerce brand previously operated a 2,000 sq ft warehouse in Kwai Chung using a traditional PTG model.

As order volume grew to 800 orders per day, five pickers were no longer sufficient. During peak seasons, error rates reached 3%, leading to frequent returns and customer complaints.

After engaging BPS Global for a warehouse assessment, the team recommended implementing a compact AMR-based GTP system and redesigning the warehouse layout.

Results after transformation:

• Picking staff reduced from 5 to 2
• Throughput increased from 450 to 1,200 order lines per hour
• Picking accuracy improved to 99.97%
• Storage capacity increased by 60% within the same space

Most importantly, the company postponed relocating to a larger warehouse, saving significant rental costs.

Tailor-Made Warehouse Solutions by BPS Global

Modern GTP solutions can integrate seamlessly with warehouse management systems (WMS), conveyors, pick-to-light systems, and robotic arms — creating a fully connected workflow from picking to sorting and dispatch.

No matter what stage your business is in, your picking strategy directly impacts operational costs and customer experience.

With extensive experience in Hong Kong and cross-border logistics, BPS Global provides end-to-end warehouse solutions — from PTG setups to full GTP transformation. From system design and equipment selection to process reengineering and daily operations support, BPS delivers one-stop solutions to help your warehouse achieve efficiency, accuracy, and scalable growth.

Contact Us today to start your Goods-to-Person upgrade journey.

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MHD Magazine (March 2026)

‍MHD sits down with Malcolm Druce, Managing Partner at BPS Global Australia, to discuss how 30 years of Asian manufacturing connections combined with deep local expertise is demystifying Chinese automation purchases and de-risking implementation for Australian businesses.

Supply chain operators are looking directly to Chinese manufacturers for innovative, cost-effective solutions. But this route requires expert knowledge in sourcing, installing, and maintaining equipment to Australian standards.

BPS Global Australia is stepping forward as a leader in this area. Malcolm Druce, Managing Partner at BPS Global Australia, says their connections to Asian manufacturing markets and local Australian expertise positions them to solve this challenge.

“We want to be able to demystify purchasing robotics and automation out of China," says Malcolm. "We don't want companies to miss out on the opportunity to buy really good quality,cost-effective equipment. But we also want to make sure that they go in with their eyes completely open, and there are no hidden surprises."

The Hong Kong advantage

BPS Global Hong Kong has been operating for over 30 years, turning over more than $35 million annually and serving over 1,000 clients across engineering and construction, logistics technology, investment and real estate,and robotics solutions. This gives BPS Australia immediate access to Asian manufacturing markets.

“They are connected to just about every single manufacturing organisation in China of any significance," Malcolm explains. This infrastructure provides BPS Australia with an edge: expertise on Chinese manufacturing capability, quality standards, and emerging technologies. The organisation can assess factories, understand equipment capabilities, and identify which manufacturers deliver on their promises.

“If necessary, we'll bring people out of BPS Hong Kong who know the equipment to assist with installations,” Malcolm notes. “We can tap into our factory knowledge, understand market trends, and help clients get the best value from Chinese manufacturers.”

Addressing the need in Australia’s market

Australian businesses looking at innovative, cost-effective equipment at trade shows or through online research face hurdles when trying to bring that technology into local operations. Often there are language barriers, different compliance requirements, installation challenges and warranty concerns. Malcolm says these roadblocks have the potential to derail promising automation projects before they have the chance to hit the ground running.

Malcolm emphasises BPS will still maintain an ‘equipment agnostic’ approach, keeping a strong pulse in analytics and operational understanding. Instaying neutral, BPS recommends the right equipment for each application rather than pushing specific brands or suppliers.

The full-service offering covers equipment selection, factory quality assessments, design and CAD drawings, Australian compliance management, installation, warranty support, and integration with warehouse management systems. BPS also has deep connections with local suppliers for complementary requirements like racking systems.

BPS can work in multiple capacities depending on client needs: as a consultant providing advice and facilitating connections, as a broker, or as a full-service integrator managing the entire process.

"Some businesses out there know automation really well, and we can support them to make their own decisions. Some don't know automation very well, and we can offer more guidance in those cases," Malcolm says.

Essentially, BPS supports businesses through two pathways: purchasing equipment through BPS as part of a full-service engagement, or buying direct from a Chinese manufacturer. In cases where the buyer chooses to purchase direct, BPS can act on the customer’s side – supporting negotiations, duediligence and freight coordination if required, while ensuring the buyer understands responsibilities such as warranty and importer-of-record requirements.

Understanding the local landscape

BPS has a deep understanding of Australian business requirements,including the compliance, safety, and physical specifications that can catch overseas manufacturers unaware.

BPS has a deep understanding of Australian business requirements,including compliance, safety, and the physical infrastructure needed to support automation.

Malcolm says the biggest mistakes that derail projects are often basic butcostly – overlooking infrastructure requirements such as fire regulations,floor quality and site connectivity.

He also emphasises the importance of safety and compliance duringinstallation. “You need to make sure that whatever you’re buying is manufactured to Australian standards, and that your installation contractors are properly covered with insurance, licences and permits,” he says.

For BPS, de-risking the purchase means ensuring warehouse infrastructure is fit for purpose, verifying factory quality and processes, and putting the right controls in place for installation – whether BPS delivers the installation directly or takes a project management role with customer-selected contractors.

This is what he describes as de-risking the purchase, ensuring businesses understand and meet all Australian requirements from day one.

Getting businesses automation-ready

Ensuring businesses are prepared for automation means assessing operational processes, IT capability, and physical infrastructure before any equipment arrives.

"When you automate, particularly with robotics, you have to change your operational processes," Malcolm emphasises. "You can't do what you've always done, throw in equipment and expect to be able to do that into the future. It won't work and you will fail."

Part of BPS's initial assessment involves analysing whether a client's warehouse management system or ERP could handle the messaging requirements ofautomated equipment. “You need to be able to send and receive the messages thatthe robotics and automation require in order to function," Malcolm explains. "If you've got a very basic ERP or an accounting system with no operational capability, you're going to struggle.”

The business also looks at extracting operational knowledge before automation implementation. "The worst cases are where knowledge sits inthe heads of the operators and no one documents the process flows,” Malcolm says.

“Automation gets installed, you realise you missed part of the workflow and all of a sudden you've got to rework it or throw it all out and start again."

The BPS approach

BPS's strength comes from the combined operational experience of its Australian team, many of whom – Malcolm included – have worked their way up through manual and automated warehouses.

This, combined with strong data analytics and design capability, allows BPS to create solutions that work for operational staff, not just procurement teams or supply chain directors. In one of its most recent major projects, feedback highlighted BPS's innovation, flexibility, quick understanding of operations, and ability to design solutions that support ground-level workers.

For BPS, success means changing how Australian businesses approach Chinese automation purchases - moving from hesitation to confidence.

"With all our experience, we are best placed to be the Australian face of Chinese equipment manufacturers," Malcolm says.

With Chinese manufacturers producing innovative equipment at competitive prices and Australian demand growing, Malcolm sees BPS's role as essential -not just facilitating sales, but ensuring successful implementations that deliver long-term value.

Malcolm references a colleague from the military’s wisdom. “Time spent in reconnaissance is time seldom wasted.” For BPS, this means thorough understanding of cross-cultural regulations, risk mitigation strategies, and business continuity processes built into every project from the start.

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