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22.08.2025 15:17
Optimising intralogistics is a crucial competitive factor for modern companies.
Those who design their internal processes efficiently and can optimise intralogistics not only save time and costs, but also increase customer satisfaction through faster and more reliable processes.
But what exactly is behind this term, and what specific measures lead to improved in-house logistics?
What Exactly Is Meant by Intralogistics?
Intralogistics forms the backbone of every manufacturing company and logistics operation. It encompasses all processes that take place within the company and is therefore clearly distinct from external logistics. While many companies focus on optimising their external supply chains, the potential of internal processes is often overlooked. Yet, it is precisely here that significant efficiency gains can be achieved, directly impacting competitiveness.
Definition and Distinction from External Logistics
Intralogistics covers all material, goods, and information flows within a company site. The German Engineering Federation (VDMA) defines it as the organisation, control, execution, and optimisation of internal material flows. Unlike external logistics, which deals with transport between different locations, intralogistics focuses on all internal processes. The key areas include:
- Goods receipt and incoming goods inspection
- Storage and inventory management
- Internal material transport
- Order picking and order processing
- Stock control and order handling
- Packaging and shipping preparation
- Goods issue and shipping processing
The importance of a well-functioning intralogistics system is often underestimated. Inefficient processes can lead to considerable additional costs. Companies that optimise their intralogistics can significantly reduce costs while increasing process speed. Modern technologies such as automated guided vehicles, automatic storage systems, and intelligent conveyor technology play an increasingly important role in this.
Challenges in Modern Intralogistics
The demands on in-house logistics have changed dramatically in recent years. Increasing product variety, smaller batch sizes, and frequent production changes require flexible solutions. At the same time, inefficient material flows lead to higher storage costs, poor material management, and outdated stock. These challenges make it all the more important to use available resources optimally and continuously improve processes.
How to Optimise Intralogistics
To optimise intralogistics, companies have various approaches at their disposal. Success largely depends on an approach that takes both technological and organisational aspects into account. A step-by-step approach has proven effective in practice, as it minimises risks and enables quick wins. The following strategies have proven to be highly effective.
Digitalisation and Automation as Key Factors
The first step in optimisation is a comprehensive assessment of current processes. Many companies still operate with outdated systems or manual workflows that waste time. By implementing modern warehouse management systems, inventory can be tracked in real time, picking routes can be optimised, and error rates can be reduced. The most important automation technologies include:
- Storage and retrieval machines for automated put-away and retrieval
shuttle systems for compact storage solutions - Automated small parts warehouses for quick access
- Picking robots for repetitive tasks
- Intelligent conveyor systems and conveyor belts
- Automated pallet conveyor technology
- Image processing systems for quality control
Anyone looking to optimise intralogistics should first analyse where the biggest time-wasters and cost drivers lie. Automated solutions offer enormous potential, and the investment often pays off within a few years through reduced personnel costs and higher throughput rates. It is important to find the right level of automation – not every process needs to be fully automated.
Improving Transport Routes and Material Flow
Another important approach is the optimisation of in-house transport routes. Companies can optimise intralogistics by analysing material flows and identifying bottlenecks. Rearranging storage areas according to access frequency can reduce walking distances by up to 40%.
Modern transport systems such as automated guided vehicles (AGVs) or autonomous mobile robots (AMRs) ensure a continuous material flow. These systems work around the clock and can be flexibly adapted to changing requirements. For the transport of smaller goods, pneumatic tube systems – like those offered by Air-Log – provide a particularly fast and efficient solution. With speeds of up to 8 metres per second, these systems reliably transport samples, documents, or small parts across the entire premises – ideal for hospitals, laboratories, and industrial operations where time is a critical factor.
Process Optimisation Through Intelligent Software
Software solutions are the heart of modern intralogistics. A well-designed warehouse management system coordinates all operations and ensures transparency. Companies that want to optimise intralogistics benefit from features such as automatic replenishment control, optimised route planning, and predictive maintenance. Integration with ERP systems allows for a holistic view of company processes.
Artificial intelligence and data-driven analyses open up further possibilities. Analysing historical data helps identify patterns and continuously improve processes. Modern picking methods significantly boost efficiency:
- Pick-by-Voice for hands-free work via voice control
- Pick-by-Light for visual guidance through light signals
- Pick-by-Vision using smart glasses and augmented reality
- Digital assistance systems to support employees
- Mobile data capture with handheld scanners and tablets
Involving and Training Employees
Technology alone is not enough to optimise intralogistics. Employees must be involved in the change process. Regular training ensures that new systems are used effectively. Ergonomic workplaces and well-thought-out processes increase employee satisfaction and reduce sickness-related absences.
Change management is a critical success factor. Resistance to new technologies can be overcome through transparent communication and gradual implementation. Employees should be taken seriously as experts in their work areas and involved in optimisation projects. Collaborative robots (cobots) can take over heavy or monotonous tasks, freeing up staff for value-adding activities.
Sustainably Improving Intralogistics with Well-Thought-Out Solutions
The possibilities for optimising intralogistics are diverse, ranging from simple organisational measures to complex automation solutions. The key to success lies in a systematic approach: first analyse, then plan, and finally implement step by step. Companies should avoid chasing every trend and instead choose solutions that match their specific requirements.
This is where Air-Log comes in: as a specialist in pneumatic tube systems, the company offers a proven and highly efficient solution for in-house logistics. Air-Log’s pneumatic tube systems have been in use for over 30 years and have proven their worth in more than 50 countries worldwide.
They are perfect for the fast and secure transport of samples, documents, and small parts – especially in time-critical environments such as hospitals, where blood samples are sent directly from the ward to the laboratory, or in industry, where material samples must quickly reach quality control.
With this technology, Air-Log helps companies take their intralogistics to the next level and achieve sustainable efficiency gains.