{"id":32815,"date":"2026-10-22T15:52:32","date_gmt":"2026-10-22T22:52:32","guid":{"rendered":"https:\/\/hughesmarino.com\/inland-empire\/blog\/2026\/10\/22\/rethinking-the-warehouse-how-embracing-automation-and-robotics-can-lead-to-meaningful-savings\/"},"modified":"2026-10-22T15:52:32","modified_gmt":"2026-10-22T22:52:32","slug":"rethinking-the-warehouse-how-embracing-automation-and-robotics-can-lead-to-meaningful-savings","status":"publish","type":"post","link":"https:\/\/hughesmarino.com\/inland-empire\/blog\/2026\/10\/22\/rethinking-the-warehouse-how-embracing-automation-and-robotics-can-lead-to-meaningful-savings\/","title":{"rendered":"Rethinking the Warehouse: How Embracing Automation and Robotics Can Lead to Meaningful Savings"},"content":{"rendered":"\n

Photo credit: APEX Companies<\/em><\/sup><\/p>\n\n\n\n

By Alex Musetti, Will Tober & Mike Paleo<\/strong><\/p>\n\n\n\n

For as long as most of us can remember, the industrial warehouse has followed a reliable formula. Racks, forklifts, aisle ways, and a floor plan built to move product efficiently from dock to shelf and back again. It\u2019s a model that has served companies well, and for good reason. It works.<\/p>\n\n\n\n

But a new set of tools is emerging that is giving some companies a chance to rethink what\u2019s possible inside their four walls. Robotics and automation technology, long proven in high-density distribution markets across Asia, is now arriving in North America at scale. For industrial tenants, it\u2019s worth understanding what it could mean for your business in the near future and beyond.<\/p>\n\n\n\n

We recently spoke with ThruPut Partners<\/a> co-founders Brian Hudock and Kevin Hume, supply chain consultants with decades of hands-on experience helping companies implement warehouse technology, and provided the Hughes Marino perspective on what these technologies actually do, who they make sense for, and what industrial tenants might want to consider as the landscape evolves.<\/p>\n\n\n\n

 <\/p>\n\n\n\n

The Traditional Warehouse Model<\/h2>\n\n\n\n

Q: Warehouse design has followed a pretty consistent model for a long time. Can you walk us through how it typically works?<\/strong><\/p>\n\n\n\n

ThruPut:<\/strong> The traditional warehouse model is built around forklifts and the aisle ways those forklifts need to move through. Your floor plan is essentially shaped by your equipment. You have racks for storage, aisleways for access and a workforce to operate it all. When volume grows, you add labor and space. It\u2019s a logical, time-tested system, and the vast majority of industrial operations around the world run on some version of it. Standard pallet rack configurations, for example, require aisle ways anywhere from 9 to 15 feet wide depending on the equipment, and lift trucks typically max out at 28 to 40 feet in height. That geometry has defined how warehouses are laid out for generations. What we\u2019re seeing now is that a new category of technology is giving companies options they didn\u2019t have before, not to replace what works, but to potentially do more with the space they have.<\/p>\n\n\n\n

 <\/p>\n\n\n\n

What Robotics Can Do for Your Space<\/h2>\n\n\n\n

Q: Can you give a concrete example of how robotics changed the space picture for one of your clients?<\/strong><\/p>\n\n\n\n

ThruPut:<\/strong> We worked with a client who, based on a traditional space analysis, determined they needed 250,000 SF. When we modeled their operation using an autonomous robotic storage and retrieval system, that number came down to 160,000 SF. Same inventory, same throughput, 90,000 SF less. At current market rates, that kind of difference can translate to millions of dollars over the life of a lease, on top of the labor and insurance savings that often come along with it. That said, results vary depending on the operation. The point isn\u2019t that everyone will see those numbers. It\u2019s that the analysis is worth doing.<\/p>\n\n\n\n

Q: How does robotics actually create those kinds of space efficiencies?<\/strong><\/p>\n\n\n\n

ThruPut:<\/strong> In a conventional warehouse, a significant portion of the floor plan is dedicated to aisle ways, space that product never actually touches. It exists purely for equipment access. Autonomous robotic systems actually work within the racking structure itself, which means those wide aisle ways are no longer required. The storage footprint can compress and build vertically in ways that were not practical before. Systems like AutoStore, for example, run robots across an aluminum grid on top of a dense storage cube, delivering bins directly to operators at workstations. There are no walking aisles and no forklift lanes, and storage density can increase up to 400% compared to conventional layouts because you’re building up and in rather than out. For operations that work primarily with full pallets rather than bins, four-way pallet shuttle systems operate on a similar principle, with autonomous robots moving pallets in four directions within the racking structure itself, handling up to around 3,300 pounds and running full warehouse height.<\/p>\n\n\n\n

\"rethinking<\/figure>\n\n\n\n

Photo credit: Mecalux<\/sup><\/em><\/p>\n\n\n\n

Beyond the footprint, forklift-related injuries are one of the most common sources of workplace incidents in industrial facilities, so reducing or eliminating that equipment can have a meaningful impact on insurance costs. These systems also operate around the clock without the variability that comes with shift changes and staffing gaps.<\/p>\n\n\n\n

Q: What does the automation landscape actually look like today for companies that are starting to explore this?<\/strong><\/p>\n\n\n\n

ThruPut:<\/strong> It\u2019s broader than most people realize, and it\u2019s useful to think of it in three buckets. The first is proven automation that many companies already have in some form: warehouse management systems, conveyors, sorters, barcode scanning and automated packing equipment. The second is what we would call current adoption technology, things that are being actively deployed right now: autonomous mobile robots for picking and transport, automated shuttle systems and warehouse execution systems that coordinate it all. The third is emerging technology: robotic arms for depalletizing, fully autonomous lift trucks and AI-driven inventory management. Most companies aren\u2019t starting at the cutting edge, and they don\u2019t need to be. The right starting point depends entirely on where your operation is today and where your biggest pressure points are, whether that\u2019s labor, space, accuracy or throughput.<\/p>\n\n\n\n

Q: What does a good candidate for warehouse automation actually look like<\/strong>?<\/strong><\/p>\n\n\n\n

ThruPut:<\/strong> The honest answer is that it depends, and figuring that out is exactly where we start. These systems are a strong fit for certain operation types and less so for others. Companies that are primarily pallet-driven, operating in high-cost real estate markets or dealing with significant labor challenges tend to see the strongest case. Seasonal operations that rely heavily on forklift flexibility may find that the traditional model still serves them better. And automation doesn\u2019t have to mean a full robotic overhaul. There are incremental steps, better warehouse management systems, smarter layouts, targeted automation in specific areas, that can add real value without a major capital commitment. Our job is always to start with the operation and work backwards to the technology, never the other way around.<\/p>\n\n\n\n

 <\/p>\n\n\n\n

The Hughes Marino Perspective<\/h2>\n\n\n\n

Q: How has your approach to advising industrial clients evolved as these technologies have become more prominent?<\/strong><\/p>\n\n\n\n

Hughes Marino:<\/strong> We\u2019re asking more questions than we used to, and earlier in the process. It used to be fairly straightforward: a client comes in with a square footage number and we go find it. We still do that, but now we want to understand the operation behind the number before we take it at face value. How is the warehouse currently set up? What equipment are they running? Have they thought about automation at all? A client who is running a forklift-dependent operation has a very different space profile than one who is open to a robotic system, and the square footage they need can look dramatically different as a result. We\u2019ve had clients come in with one number in mind and end up in a meaningfully different and better situation once we dug into the details. Other times the number they came in with was exactly right. Either way, the conversation is richer for asking. We also think about it differently now in terms of how we measure space. The industry has long talked about square footage, but the more relevant conversation for an automated warehouse is often cubic footage, how much volume can you actually store and move within a given footprint, not just how many square feet it covers.<\/p>\n\n\n\n

Q: Are there building specifications you now factor into your search that you might not have prioritized a few years ago?<\/strong><\/p>\n\n\n\n

Hughes Marino:<\/strong> Definitely. Things like floor flatness, ceiling clear height and power capacity used to be secondary considerations for many industrial clients. Now we\u2019re asking about them upfront, because those specs determine what technology a building can support down the road. Certain robotic systems require very precise floor flatness tolerances that older buildings simply cannot meet. Higher clear heights allow for the kind of vertical storage density that makes these systems work. And the electrical load requirements for automated systems are substantially higher than a conventional forklift operation, so a building’s power infrastructure matters in a way it didn\u2019t before. A client who\u2019s open to automation, or who might want that option in year five of a 10-year lease, needs a building that can accommodate it. If we discover that mismatch after a lease is signed, the options get expensive fast.<\/p>\n\n\n\n

Q: You have worked with ThruPut Partners on industrial client engagements. What does that look like in practice?<\/strong><\/p>\n\n\n\n

Hughes Marino:<\/strong> We\u2019ve brought ThruPut in on the front end of industrial client work to take a closer look at the operational picture alongside our real estate analysis. They help us understand what a client’s space needs actually look like once you account for how their operation works and what technology options might apply. That directly shapes what we are looking for in a building: the square footage, the specs, the market. The reason we do it early is that discovering a mismatch between a building and an operation after a lease is signed is an expensive problem. Retrofitting mid-lease is costly and disruptive, and some building limitations simply cannot be worked around. Getting that picture clear on the front end is always the better path.<\/p>\n\n\n\n

Q: What do companies most often overlook when evaluating industrial space<\/strong>?<\/strong><\/p>\n\n\n\n

Hughes Marino:<\/strong> Two things come up consistently. The first is not accounting for where their operation is heading, not just where it is today. The second is underestimating how much the building itself matters. It\u2019s bigger than most people realize, and it shows up in more ways than just rent. If you\u2019ve committed to more space than you needed, that cost is sitting on your books every month for the life of the lease. The difference between a right-sized space and an oversized one adds up quickly. But beyond that, a building that cannot support the technology your operation eventually needs becomes a real constraint. You\u2019re either stuck working around it or facing a costly retrofit. And there\u2019s an opportunity cost that\u2019s harder to quantify, but just as real: a company locked into the wrong space for 10 years isn\u2019t well positioned to take advantage of what\u2019s becoming available in the market right now. That\u2019s ultimately why we invest so much in the front-end process. Getting it right before you sign is almost always less expensive than solving it after.<\/p>\n\n\n\n

Q: Why should industrial tenants be paying attention to robotics and warehouse technology right now?<\/strong><\/p>\n\n\n\n

Hughes Marino: <\/strong>Because the window to get ahead of it is open right now, and it won’t be forever. Robotics and warehouse technology is something that\u2019s going to become increasingly relevant in the next five to 10 years. These trends have already played out in high-density markets across Asia, where space constraints forced a level of innovation that\u2019s now making its way to the United States. Most industrial companies don\u2019t have deep warehouse technology expertise in house, and they shouldn\u2019t necessarily have to. Being able to introduce this conversation early, before a lease is signed or a major real estate decision is made, makes a real difference. We aren\u2019t in the business of telling clients what they need to do. We are in the business of making sure they have the full picture when they decide.<\/p>\n","protected":false},"excerpt":{"rendered":"

Photo credit: APEX Companies By Alex Musetti, Will Tober & Mike Paleo For as long as most of us can remember, the industrial warehouse has followed a reliable formula. Racks, forklifts, aisle ways, and a floor plan built to move product efficiently from dock to shelf and back again. It\u2019s a model that has served […]<\/p>\n","protected":false},"author":38,"featured_media":32816,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":"","_links_to":"","_links_to_target":""},"categories":[1062],"tags":[],"publication":[],"video_type":[],"coauthors":[1017,1051,1126],"class_list":["post-32815","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-hm-blog"],"acf":[],"yoast_head":"\nRethinking the Warehouse: How Embracing Automation and Robotics Can Lead to Meaningful Savings - Hughes Marino Inland Empire<\/title>\n<meta name=\"description\" content=\"We recently spoke with ThruPut Partners and provided the Hughes Marino perspective on what these technologies actually do...\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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