Automated Pallet Storage Warehouse for Battery Manufacturing Plants

Applying Advanced Technology to Material Storage in Automotive Battery Manufacturing

One of Vietnam’s leading lithium battery manufacturers—supplying electric vehicles and electric buses—partnered with ETEK to deploy an automated pallet storage warehouse. This project marks a major step in supporting an annual production capacity of up to 100,000 battery packs, requiring a warehouse system that is intelligent, highly accurate, and capable of continuous operation.

Challenges in ETEK’s First Large-Scale Automated Warehouse Project

Although ETEK has extensive experience in industrial automation, this was the company’s first large-scale AS/RS automated warehouse project. It required thorough preparation in system design, equipment sourcing, cost planning, and the development of robust warehouse management software.
Handling a large number of SKUs with strict accuracy requirements posed an additional challenge, demanding full mastery of both hardware and warehouse control software from ETEK’s engineering team.

Technology Solution: AS/RS System Integrated with Augmented Operations Assistance (AOA)

ETEK developed an AS/RS automated warehouse solution integrating multiple advanced technologies:

• Warehouse area: 3,500 m²
• Storage capacity: 3,200 pallets
• Stacker cranes: 5 units
• RGVs (Rail Guided Vehicles): 2 units
• Automated conveyors: 1 infeed/outfeed system
• Stretch wrapping machine: Semi-automatic
• Control & monitoring software: End-to-end system operation management

Notably, the control software is integrated with AOA (Augmented Operations Assistance) technology, enabling real-time system monitoring, remote maintenance support, and rapid fault detection.

How the Automated Pallet Storage System Operates

The entire system operates without human intervention during inbound and outbound processes. After pallets are wrapped by the stretch wrapper, they are transferred into the system by AGV forklifts. RGVs then receive the pallets and transport them to the storage zone, where stacker cranes automatically store or retrieve pallets from designated locations.

The intelligent warehouse management software orchestrates all activities—from data registration and empty-slot allocation to optimized material flow throughout the warehouse.

Outstanding Performance of the AS/RS Warehouse

After nearly four months of deployment and fine-tuning, the automated pallet warehouse has been operating stably, delivering impressive results:

• Throughput: 150 pallets/hour
• Speed: 2× faster than manual warehouses
• Space efficiency: 1.3× higher than traditional models
• Accuracy rate: 100%
• Continuous operation: 24/7

Practical Benefits for the Manufacturing Plant

• Increased labor productivity: Automation accelerates inbound/outbound processes, reduces downtime, and maximizes efficiency.
• Guaranteed accuracy: Automated control eliminates human errors, ensuring correct and complete handling of goods.
• Optimized space utilization: Smart warehouse design maximizes floor space usage.
• Efficient inventory management: Software enables real-time inventory visibility.
• Reduced product loss: Full automation minimizes damage and loss during operations.
• Proactive maintenance: AOA technology enables early fault detection and remote support, enhancing system stability.

The automated AS/RS pallet storage warehouse is a key enabler for manufacturers seeking to modernize operations, reduce costs, and significantly boost productivity. This project represents a solid first milestone for ETEK in the field of smart, automated warehousing in Vietnam.