Automated pallet storage solutions are transforming the way modern warehouses operate, promising faster throughput, greater accuracy, and a more scalable approach to managing complex inventories. But not all automation delivers the same results.
Without the right design strategy behind it, even the most advanced system can underperform, leading to bottlenecks, inefficiencies and missed ROI targets.
In short, the very solution meant to increase efficiency can actually reduce throughput — unless it’s designed and engineered with flow in mind.
At Thistle Systems, we understand that true warehouse performance comes from more than just installing the most energy-efficient automated storage solution in the world. It comes from designing it around your operation, your data, and your business goals.
The Challenge: Automation Without Flow Is Just Expensive Storage
Adding more SKUs in less space may solve your capacity issues, but it increases the complexity of picking and replenishment. With hundreds or even thousands of SKUs stored in deep lanes or grid-based systems, poorly planned layouts or one-size-fits-all solutions can result in:
- Access delays for high-velocity items
- Conflicts between inbound and outbound tasks
- Lift and shuttle congestion during peak hours
- Slower pick rates due to inefficient product placement
The problem isn’t the technology — it’s the way it’s been designed and applied.
Automated storage systems like Autocube® offer incredible potential, but they require intelligent layout planning, SKU analysis, and throughput modelling to deliver on that promise.
Our Approach: Data-Driven Design, Powered by In-House Simulation
At Thistle Systems, we don’t start with hardware. We start with data.
Before we propose a solution, our design team uses our in-house simulation software to analyse every element of your warehouse operation:
- SKU profiles and turnover velocity
- Order volumes and pick frequencies
- Inbound and outbound flows
- System constraints like lift speeds, shuttle availability, and grid layout
This enables us to simulate real-world performance scenarios before a single component is installed — from single-shift operations to full 24/7 models.
We can test multiple configurations, identify potential bottlenecks, and optimise for peak efficiency — giving you confidence that the system will work exactly as expected.
Designing for Throughput, Not Just Capacity Maximisation
Our Autocube® systems are engineered to avoid the common pitfalls of high-density warehousing by:
- Placing fast-moving SKUs for easy, low-interference access
- Separating inbound and outbound traffic flows to eliminate congestion
- Optimising runways, lifts and carriers to meet throughput requirements
- Using smart software to optimise shuttle movement and lift timing
- Using intelligent algorithms to automatically move pallets closer to staging areas to speed up outbound tasks and times
- Creating scalable configurations that can adapt as SKU ranges evolve
We don’t just install systems — we design performance. That’s the new Max the Cube approach which is optimising automated warehouses storing as little as 700 pallets to several thousand pallet positions.
What Sets Thistle Systems Apart
- Proven expertise in designing and delivering automated pallet storage systems across manufacturing, food & drink, 3PL, and cold stores
- Exclusive supplier of Autocube®, powered by Logiqs’ globally proven 4-Way shuttle technology
- In-house design, simulation, engineering, and commissioning teams — delivering end-to-end control
- Custom software integration with WMS/ERP platforms for total visibility and control
- Performance-first mindset, where we optimise for speed, flow, and long-term ROI — not just storage volume
From Simulation to Installation — and Beyond
Whether you’re building a new warehouse or retrofitting an existing site, Thistle Systems offers a comprehensive design and delivery service for automated pallet storage. Every project includes:
- Full operational analysis and simulation
- Layout and flow optimisation
- Detailed ROI modelling
- Mechanical and electrical engineering
- Software and controls integration
- On-site installation, commissioning, and UK-based support
It’s how we ensure that every system we deliver performs not just from day one — but for years to come.
Conclusion: Automation Without Design and Data Is a Major Risk.
Investing in an automated warehouse solution is a strategic decision. The right design partner can be the difference between unlocking transformative efficiency — or creating new constraints.
At Thistle Systems, we combine advanced simulation tools with years of real-world experience to deliver automated pallet storage solutions that work exactly as they should — fast, efficient, and future-ready.
Thinking about automating your warehouse? Let’s design it right.
Contact Thistle Systems today to book a discovery session with our design team and see how simulation-led planning can transform your warehouse.
Looking to Automate your Picking Operations?
If Automation is right for you, however your requirements differ from AutoCube’s offerings, explore our options: Brightpick – A Robotic Order Picking System. From in-aisle robotic picking solutions to fully automated goods-to-person systems, we have a solution that can be tailored to suit your requirements.
