Designing a large-scale warehouse isn’t just about stacking shelves and plugging in robots. For automation and industrial engineers, it’s a complex puzzle of infrastructure, logistics, and long-term planning. From the layout of racking systems to the maintenance of forklifts and automated guided vehicles (AGVs), every decision impacts efficiency, safety, and scalability.
Let’s break down how engineers approach warehouse infrastructure planning and how innovations like the PowerHIVE™ system are reshaping the way we think about power management and equipment uptime.
Infrastructure Planning: More Than Just Square Footage
When engineers begin planning a warehouse, they’re not just thinking about how much space is needed. They’re also considering how that space will function.
Key considerations include:
- Material flow: How will goods move from receiving to storage to shipping?
- Automation zones: Where will robotics, conveyors, and ASRS (automated storage and retrieval systems) operate?
- Power distribution: How will energy be delivered to high-demand systems like chargers, conveyors, and robotic arms?
- Maintenance access: Can technicians easily reach equipment for servicing without disrupting operations?
These decisions are foundational. A poorly placed charging station or bottlenecked aisle can cost thousands in lost productivity.
Forklift and Automation Equipment: Planning for Uptime
Forklifts, whether manual or automated, are the lifeblood of many warehouse operations. But they’re also maintenance-intensive. Engineers must plan for:
- Battery charging and swapping stations
- Preventive maintenance schedules
- Fleet management systems
- Downtime mitigation strategies
Implementing a planned maintenance (PM) or full maintenance (FM) program can significantly reduce unexpected breakdowns and extend equipment life. Engineers often work with operations teams to define service intervals, track usage hours, and monitor wear on critical components like lift chains, hydraulic systems, and braking mechanisms.
The Power Problem: Why Battery Management Matters
One of the biggest challenges in modern warehouses is power management, especially for forklifts. Traditional battery charging rooms take up valuable space, require complex electrical infrastructure, and often lead to downtime during battery swaps.
That’s where the PowerHIVE™ system comes in.
PowerHIVE™ is a fully automated forklift battery management system that reloads batteries in under three minutes. It eliminates the need for manual battery swaps, reduces the footprint of charging areas, and improves operator safety. For engineers, this means:
- Simplified infrastructure: One electrical drop can power 100 forklifts, and battery rooms are placed with a 600 ft2 centralized solution
- Increased uptime: No more waiting for batteries to charge
- Energy efficiency: Smart charging reduces peak power costs and extends battery life
- Scalability: One battery size can serve multiple equipment types.
A 20-truck fleet using PowerHIVE™ across three shifts can save over 20,000 charging hours per year and reduce carbon emissions by 118 metric tons.
Designing for Maintenance: Future-Proofing the Facility
Engineers must also plan for the long-term care and reliability of automation systems. This includes:
- Access points for technicians to service conveyors, robotics, and sensors
- Redundancy in critical systems to avoid single points of failure
- Data integration for predictive maintenance using IoT and AI
- Training areas for operators and maintenance staff
As automation becomes more complex, so does the need for smart diagnostics and remote monitoring. Engineers often collaborate with IT and operations to ensure systems are integrated with warehouse management software (WMS) and enterprise resource planning (ERP) platforms.
The Engineer’s Role: Bridging Vision and Reality
Ultimately, automation and industrial engineers are the bridge between vision and execution. They translate operational goals into physical systems that are efficient, safe, and scalable. Their work touches everything from:
- Structural design (floor loads, racking systems)
- Electrical planning (power drops, backup systems)
- Mechanical systems (HVAC, compressed air, hydraulics)
- Technology integration (robotics, sensors, software)
And with tools like PowerHIVE™, they now have more options than ever to optimize uptime, reduce costs, and future-proof operations.
Putting It All Into Practice
Warehouse infrastructure planning is no longer just about space; it’s about systems thinking. Engineers must consider how every piece of equipment, every power drop, and every maintenance plan fits into a larger ecosystem of automation and logistics.
By embracing innovations like PowerHIVE™ and designing with maintenance in mind, engineers can build smarter, more resilient warehouses that are ready for the demands of tomorrow.
Are you an industrial or automation engineer planning a large project? Let Concentric help with the planning and execution. Contact us today for more information!