Autonomous Intralogistics 2025: AMRs, hybrid systems and smart networking
Intralogistics is undergoing a phase of profound change. High delivery speeds, volatile markets, a shortage of skilled workers, and increasing cost pressures require solutions that are flexible, efficient, and sustainable . Traditional, rigid conveyor systems are increasingly reaching their limits.
One of the most exciting developments is the use of autonomous mobile robots (AMRs) . But the future of intralogistics goes even further: Only in combination with hybrid systems , artificial intelligence , digital twins , and a clear focus on safety and sustainability will a holistic concept emerge that sets standards for 2025 and beyond.
Autonomous Mobile Robots (AMR) as Game Changers
AMRs are the next evolutionary stage of driverless transport systems. Unlike traditional AGVs (Automated Guided Vehicles), which require permanently installed guidelines or magnetic strips, AMRs navigate through the warehouse completely autonomously using sensors, cameras, and AI .
The advantages at a glance:
- Flexibility : No rigid paths, easy adaptation to new layouts.
- Scalability : AMR fleets can be expanded as needed.
- Cost reduction : Less manual transport, optimized material flows.
In large distribution centers, AMRs are no longer an exception. They handle picking, replenishment, and transport between workstations – around the clock.
Hybrid intralogistics systems: AMRs and conveyor technology in interaction
Despite all their advantages, AMRs will not completely replace traditional conveyor technology. Rather, hybrid systems are emerging that combine the best of both worlds:
- Conveyor systems handle high throughput on fixed routes .
- AMRs take care of flexible transport and local distribution .
Example: A shuttle system transports goods from the high-bay warehouse to a transfer station, where an AMR takes over transport to the assembly line or packaging. This combination ensures maximum efficiency while maintaining high flexibility.
AI & IoT for intelligent control
Autonomy doesn't mean chaos—quite the opposite: The control of modern AMR fleets is based on AI algorithms and IoT connectivity . AMRs also connect with Warehouse Execution Systems (WES) or Manufacturing Execution Systems (MES) . Via IoT interfaces, they are part of a seamless digital production and logistics chain.
Predictive Routing
AI calculates optimal routes in real time, avoids bottlenecks and adapts to changes in material flow.
Dynamic order distribution
Orders are automatically assigned to the AMRs with the best availability.
Energy optimization
AMRs drive to the charging station autonomously and plan their routes to minimize idle times.
Simulation & digital twins: Planning without risk
Another key trend is virtual commissioning . Digital twins allow material flow, AMR movements, and interfaces to be simulated before actual implementation .
Tools like iPhysics enable:
- 3D simulation of AMR fleets .
- Testing control logic, layouts and security concepts .
- Cost and time savings through early error detection.
This not only reduces risks but also significantly shortens the time until actual commissioning.
Safety & Standards in Autonomous Systems
Where machines operate autonomously, safety is a top priority . ISO 3691-4 , which defines safety requirements for automated guided vehicles, applies particularly to AMRs.
In addition, companies must:
- Implement collision protection (laser scanner, LiDAR).
- Implement cybersecurity measures to prevent manipulation.
- Ensure safe human-robot interaction – e.g., through clear zones and signaling.
A well-thought-out security strategy is not only a legal requirement, but also a crucial factor for trust and acceptance.
Sustainability in intralogistics
Autonomous systems also contribute to green logistics . AMRs reduce unnecessary journeys , optimize energy consumption, and enable demand-oriented transport.
In combination with intelligent control systems, they can:
- Reduce CO₂ emissions .
- Use resources more efficiently (e.g. less storage space due to dynamic processes).
- Improve green KPIs for ESG reporting.
Companies that integrate sustainability into their intralogistics create competitive advantages while simultaneously meeting legal requirements.
Conclusion & Outlook
AMRs are far more than a short-term trend – they are a central building block for the intralogistics of the future. Only in combination with hybrid systems, AI-controlled processes, simulation and a strong focus on safety and sustainability does a holistic concept emerge. As a specialized partner in the field of intralogistics, WIMTECH closely follows the latest developments. This way, we ensure that our projects are implemented using state-of-the-art technology and that plant manufacturers are supported efficiently, flexibly and safely in their material flow solutions. Every project is unique, but our expertise allows us to apply the latest standards and technologies in a targeted manner to create resilient and efficient systems in the long term. Those who invest in autonomous intralogistics today not only benefit from increased efficiency and cost advantages, but also secure a decisive advantage in a dynamic market.
„Flexibility is the key to success in intralogistics. AMRs and traditional conveyor technology complement each other perfectly to create future-proof systems.”
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