Where do most automated warehouses fail? – 5 critical areas where poor lubrication reduces system availability

In modern intralogistics, automatic lubrication is no longer a “nice-to-have” — it has become a basic requirement. A foundation for long-term reliability and strategic maintenance planning. Here’s why.

Automated warehouse systems today are complex mechanical networks operating under heavy loads: AS/RS machines, robot arms, spiral lifts, conveyor lines, forklifts and AGVs all work together. Many maintenance and engineering managers report the same pattern: even if the system shows high availability on paper, in reality small stops, extra noise and fluctuating energy consumption begin to appear.

Based on manufacturer data and real measurements from large distribution centers, most of these early symptoms can be traced back to insufficient or inconsistent lubrication.

Simatec’s intralogistics measurements — including the well-known Coop Schafisheim case — clearly show that lubrication issues directly influence energy consumption, vibration levels and the lifetime of critical components.

Why is automatic lubrication now a basic requirement in intralogistics?

Manual lubrication is always intermittent, while the mechanical load on lubrication points is continuous. These two will never match — especially not in a 24/7 operation.

According to EPTDA data referenced by Simatec, continuous lubrication can increase the lifetime of bearings, chains and linear guides by up to 30%.

Automatic lubrication delivers a stable, micro-dosed lubricant film on critical parts. For conveyors, robots and AS/RS machines, this is one of the most important stabilizing factors for smooth operation.

Let’s see the 5 critical areas where poor lubrication reduces system availability:

1. AS/RS systems – the highest wear risk on rails and chains

Failures in automated storage and retrieval systems are not only costly in parts (Simatec’s intralogistics study shows €6,000–15,000 per year), but also cause serious downtime.

Most issues are linked to lubrication problems such as:

• dry running,
• positioning errors,
• increased vibration,
• rising motor load.

Automatic lubrication creates smooth, consistent motion. Engineering managers often notice this immediately: vibration drops, noise is reduced, and the system becomes more predictable.

2. Conveyor systems – energy consumption shows the problem first

Conveyors are among the biggest energy consumers in any warehouse. If bearings or chains run dry, motor current increases immediately.

According to Coop Schafisheim measurements, automatic lubrication resulted in:

• 0.2 A motor current reduction per motor,
• on 1,116 motors this meant 1,340 kWh saved per day,
• and roughly 90,000 CHF energy savings per year.

In most intralogistics environments, this is one of the fastest measurable benefits of automatic lubrication — a clear, quantifiable OPEX reduction.

3. Spiral lifts and vertical transport – manual lubrication is practically impossible

Spiral lifts operate under continuous load, while their lubrication points are often hard to reach. Because manual lubrication cannot be done frequently enough, typical symptoms appear:

• popping or cracking noises,
• jerky movement,
• energy loss,
• slower cycle times.

Automatic lubrication ensures a consistent lubricant film — independent of manual routines — and stabilizes the entire lifting mechanism.

4. Robot arms and pick-and-place systems – accurate motion depends on stable lubrication

In robotic systems, lubrication quality directly affects precision. Even small friction variations in joints, ball screws or linear units can cause:

• cycle time fluctuations,
• positioning errors,
• vibration,
• premature wear.

Simalube automatic lubricators provide continuous lubrication, and in most robot cells they noticeably improve smoothness and motion accuracy — often without any mechanical modification.

5. Forklifts and AGV/AMR vehicles – often the most neglected elements of intralogistics

Forklift mast chains operate under extreme loads, yet lubrication is often inconsistent. According to Simatec’s study, mast chain issues can cost €5,000–25,000 per year.

Chain elongation, squeaking and uneven lifting are all typical signs of dry running.

Here, automatic lubrication is not a convenience feature — it is a fundamental requirement for reliable and safe operation.

Where does automatic lubrication deliver the fastest ROI?

Based on real intralogistics experience, the fastest return on investment is seen in:

• 24/7 warehouse operations,
• high or hard-to-reach lubrication points,
• large conveyor systems with increasing energy use,
• robot cells and pick-and-place units,
• intensively used forklift and AGV fleets.

ROI is mainly measurable: energy savings, longer component life, fewer unexpected failures and reduced maintenance workload.

Most failures in intralogistics do not start in the machine — they start in the lubrication.

Those who recognize the importance of automatic lubrication early gain more predictable system availability, better energy efficiency and lower maintenance costs. Experience shows that this is one of the fastest-paying operational improvements in an automated warehouse.

If you have questions, our specialists are ready to help — whether it’s selecting the right lubricant, setting up the dispensers or choosing the correct automatic lubrication system.

Visit our dedicated webshop for automatic lubrication >>HERE<<