Warehouse Transformation with Vertical Lifts and Integrated Systems:
Octopus Energy, a leading UK energy company, has a clear mission: to provide sustainable energy solutions while contributing to the fight against climate change. Their recent expansion into a new UK facility in Slough marked a crucial phase in up-scaling their operations, particularly for the distribution of heat pumps, solar panels, and associated components to their nationwide customer base.
As Octopus Energy moved into their first UK warehouse, traditional racking systems were planned for storing and managing their inventory. However, at an Industore event in 2023, Octopus saw first-hand the benefits of automated storage and retrieval systems, specifically, The Hänel Lean-Lift. This vertical lift module (VLM) is widely regarded as the world’s leading Automated Storage and Retrieval System (AS/RS).
With a growing , technical product range, fast order turnaround requirements, and already restrictive warehouse space, Octopus Energy recognised the advantages of adopting a more efficient storage and retrieval solution. Perhaps the key challenge Octopus Energy faced was the inefficient use of space in their facility, which was already overcrowded with inventory, despite having significant height available. The Lean-Lift made light work of this issue – being designed to very densely store inventory at height, on a very small footprint.
Watch: Octopus Energy's Senior Operations Manager on achieving 10x efficiency with Industore.
AS/RS Project Manager, Henoc Bananga:
“The Lean-Lifts provided the perfect solution to Octopus. They efficiently use the full warehouse height, freeing up valuable floor space and therefore generating a larger space for bulky items and pallet storage. This has empowered Octopus to store an enormous volume of critical, fast-moving components – held on 99 shelves across the three lifts, while boosting picking accuracy, speed, and safety.”
The Lean-Lifts present items directly to operators at an ergonomic height, eliminating the need for ladders, reducing manual errors, and enabling the fulfilment of multiple orders simultaneously. Thanks to our proprietary WMS (warehouse management system), Hänel Soft, Industore managed to integrate perfectly with Octopus Energy’s existing stock-keeping software (Minster Edge), ensuring total, real-time inventory control, as well as quick access to parts, and all the benefits that go with it. Built-in security and safety features, including PIN protection, emergency stop functions, and safety light barriers ensure compliance with health and safety regulations, while protecting stock and employees alike. Since the installation of the Lean-Lifts, Octopus Energy has reported significant improvements in their operations
What is batch picking?
Batch picking allows Octopus to prepare nine, similar orders at once, per machine, thereby greatly improving pick speed and accuracy.
Barcode scanners attached to each Lean-Lift allow pickers to associate generic boxes on mobile racking to each individual order. Once all the boxes are registered to a temporary location on the racking, the Lean-Lift automatically starts to retrieve the trays with the relevant products on them, instructing the picker how many items in total they need to complete the full nine orders. To ensure the correct product is retrieved from the Lean-Lift every time, the Lean-Lift uses its pick to light technology, clearly marking each piece of inventory with a red light – making choosing the right product clear and fast. You can read more about super fast picking here.
Operational Benefits of AS/RS
In addition to the operational benefits, Octopus Energy embraced Industore’s customisation options. The Lean-Lifts were finished in Octopus Energy’s signature colours and branded with Industore-designed M3 stickers, aligning with their company image. Industore recognises the importance of branding, whether our lifts are customer-facing or otherwise – consistent, strong branding fosters positive interaction, which in turn enhances brand and fraternity – extending to contentment and in turn, customer satisfaction. Industore’s machines can be customised with any RAL colour or branding, and are powder coated with an eco-friendly, shock-proof finish – aligning with both Octopus Energy’s and Industore’s commitment to sustainability.
Darren Firth again: “Today, we pick multiple orders at once, and more quickly than ever before, by picking all the relevant parts for all the existing orders at the same time. It means we never have to call a shelf more than once per nine orders, let alone traipse to different areas of the warehouse, manually eye-balling for the right parts. We’re really achieving 10x the throughput, with three times less resource. With regards to the branding, everything about Octopus is really ‘out there’. Our forklifts, vans, offices – it’s all pink and purple, and it’s great that our automated storage systems with Industore are now too.”
Further work at new sites:
In recognition of the system’s success, Octopus Energy has ordered five additional Lean-Lifts, which will expand their operational capacity even further. With the ability to store more items in less space, their operations are future-proofed, for continued growth.
Industore’s Hänel Lean-Lift system has significantly transformed the way Octopus Energy manages its warehouse operations. By improving storage capacity, speed, accuracy, and safety, Octopus Energy have been able to enhance service delivery, meeting the high, and increasing demand for its renewable energy solutions. The successful integration and rapid improvements have cemented Industore’s role as a trusted partner in their ongoing expansion.
As with all Industore projects, the Octopus solution was delivered on time and in-budget, and without operational disruption – all this, despite the facility being partially operational during the installation. As Octopus Energy continues to grow, the installation of additional Lean-Lifts will enable them to boost further their operational efficiency, while supporting their broader mission of providing tip-top customer satisfaction, and getting on with their mission, to provide sustainable energy to households across the UK, one house at a time
