DHL & Automate-X: Inside NZ’s Most Advanced Healthcare Warehouse
Share on
When global logistics giant DHL Supply Chain set out to build New Zealand's most advanced Life Sciences and Healthcare (LSH) facility, they didn't just need a warehouse; they needed a precision-engineered ecosystem.
They required a facility capable of handling critical pharmaceuticals, vaccines, and medical devices with 100% accuracy, total traceability, and zero margin for error. To achieve this level of operational excellence, they turned to Automate-X.
We are proud to announce the official opening of the Te Kapua Drive facility in Auckland—a NZ$90M investment that sets a new benchmark for logistics in Oceania. As the locally-based system integrator, Automate-X was responsible for the installation, calibration, and training for the fleet of 41 Geek+ robots that now form the heartbeat of this operation.
The Challenge: Precision Logistics at Scale
Healthcare logistics is often described as the "Olympic Games" of warehousing. Unlike standard retail fulfillment, the stakes here are life and death. The new 14,100 square metre site needed to serve the rising demand for healthcare in New Zealand while strictly adhering to Good Distribution Practice (GDP).
DHL presented us with a complex set of requirements:
- Maximize Density: Store more product in a smaller footprint to combat rising Auckland industrial real estate costs.
- Ensure Safety: Drastically reduce manual handling risks for staff dealing with heavy repetitive lifting.
- Scale Rapidly: The system had to support direct-to-pharmacy and direct-to-patient distribution models immediately upon go-live.
- Temperature Integrity: Maintain strict temperature controls for sensitive biopharma products.
The Solution: A Record-Breaking Deployment
To meet these demands, Automate-X designed and deployed a Goods-to-Person (GTP) solution using the largest fleet of autonomous mobile robots (AMRs) ever operated by a 3PL provider in New Zealand.
By integrating 41 Geek+ robots, we completely transformed the picking process. In a traditional warehouse, pickers spend up to 70% of their shift walking up and down aisles. At Te Kapua, the robots bring the inventory shelves directly to the picking station.
How the System Works
- Inbound: Goods are received and loaded into mobile racks.
- Storage: The Geek+ robots autonomously transport these racks to high-density storage zones, eliminating the need for wide aisles required by forklifts.
- Picking: When an order is received—whether for a single vaccine vial or a bulk pharmacy order—the robot retrieves the specific rack and delivers it to a workstation. The operator picks the item, and the robot returns the rack to storage.
This "no-walk" workflow drastically increases picking speed and accuracy, ensuring that urgent medical supplies reach patients faster.
Mastering the Cold Chain
One of the unique aspects of this project was integrating robotics into a highly regulated environment. The Te Kapua facility features:
- 12,000 Pallet Spaces: Utilizing Very Narrow Aisle (VNA) storage for bulk reserves.
- Multi-Zone Climate Control: The facility manages environments ranging from ambient (15–25°C) to chilled (2–8°C) and frozen (-30°C).
- The "Cool Chain" Advantage: Robots are immune to the cold. By deploying automation in temperature-controlled zones, we reduce the time human staff must spend in uncomfortable environments, further improving workplace health and safety.
Sustainability by Design
At Automate-X, we believe that modern automation must drive sustainability. The Te Kapua facility has achieved a 5-Star Green Star rating, utilizing 100% renewable electricity and rainwater harvesting.
Our robotic solutions contribute directly to this eco-friendly footprint. Because AMRs do not require floodlighting to navigate, sections of the warehouse can operate in "lights-out" mode, significantly reducing energy consumption. Furthermore, the high-density storage reduces the overall cubic volume that requires air conditioning, lowering the load on the HVAC systems.
The Automate-X Difference: Local Expertise
A project of this magnitude requires more than just shipping hardware; it requires boots on the ground.
"Locally based warehouse automation integrator Automate-X installed the Geek+ robots and trained DHL's team to manage ongoing calibration and maintenance," notes the official project release.
This is the core of our value proposition as a warehouse automation integrator. We didn't just install the robots; we empowered the DHL team. We provided extensive training on mechatronics and data analysis, helping DHL upskill their local workforce from manual handlers to robot fleet managers.
The Result: Future-Proof Logistics
"The Te Kapua site future-proofs our ability to efficiently, safely, and sustainably distribute critical and life-saving pharmaceutical and healthcare products," says Javier Bilbao, CEO of DHL Supply Chain Asia Pacific.
For Automate-X, this project confirms our position as the leading system integrator in the region. We have proven that NZ and AU businesses can deploy world-class automation that rivals any facility in Europe or North America.
Ready to Upgrade Your Operation?
You don't need to be a global giant to benefit from intelligent automation. Whether you are running a pharmaceutical distribution centre, a spare parts depot, or an e-commerce hub, the principles remain the same: reduce travel time, increase density, and improve safety.
Contact Automate-X today to discuss how we can tailor a Geek+ solution for your specific needs.