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Automate 3PL Warehouses Without Rebuilding

As a 3PL operator, you know the dilemma: your clients expect fast, accurate fulfillment – but thin margins and fluctuating volumes make traditional automation investments a risk. NEO automates your existing shelf-based warehouse without reconstruction, without heavy upfront cost, and with a pricing model that fits 3PL contracts.

NEOintralogistics automates 3PL warehouses with existing shelving on a pay-per-pick basis. AMR robots bring bins from the shelves to a goods-to-person station - no reconstruction, no heavy investment. Costs are per pick and scale with volume. Go-live in 6-8 weeks. 3PL operators reduce picking labor by up to 70% and onboard new clients faster.

The 3PL Warehouse Challenge

3PL operators face a unique combination of operational constraints:

Multi-client fulfillment

Every client brings a different SKU mix, different packaging requirements, and different SLA expectations. Your warehouse has to serve all of them in parallel.

Volume fluctuations

Seasonal peaks, campaign spikes, and client onboarding create unpredictable volume swings. The next client offboarding can drop volume just as quickly.

Margin pressure

3PL contracts are tightly priced. A traditional automation project with a €500,000 investment cannot be justified on a single client contract.

Dependency on temp labor

Peak seasons drive a significant staffing surge - typically 30 to 50% additional temp labor. Expensive, hard to find, training-intensive. And the question remains: who do you keep on payroll in February when volume drops back?

Existing buildings

You operate in leased warehouses with existing infrastructure. A new-build or complete redesign is not an option.

The result: many 3PL operators do not automate at all – and lose competitiveness and margin because of it.

Operator at the NEO:pickstation in a 3PL warehouse

Why NEO for 3PL Operators?

NEO was built for exactly the situation most 3PL operators are in: existing shelving, variable volumes, tight margins.

Pay-per-pick instead of CapEx: You pay per pick - not per robot, not per month. When a client’s volume drops, your automation cost drops with it. When a new client comes on board, you scale capacity up. The model fits 3PL contracts because it ties automation cost directly to fulfillment revenue. Learn more about pay-per-pick

Retrofit instead of rebuild: The NEO:runner robots navigate your existing aisles (minimum 85 cm width). There is no reconstruction, no shelf replacement, and no operational downtime. Other client areas in the warehouse continue running undisturbed during installation. How the retrofit works

NEO:runner navigating existing racking aisle - top-down view

Fast to Go-Live, Flexibly Scalable

Go-live in 6-8 weeks: From order confirmation to first automated pick takes 6-8 weeks. That is fast enough to onboard new 3PL clients with automated fulfillment capacity - not after an 18-month construction project.

70% less picking labor: In the automated zone, manual picking effort is reduced by 70%. During peaks, that means: less dependency on expensive temp workers, less training time, more consistent quality.

Multi-client capable: NEO:os manages SKU data, storage locations, and orders on a per-tenant basis. You can run different client volumes through the same system - with cleanly separated order management.

Operator at picking workstation - collaborative picking with robots for 3PL peak capacity

Collaborative Picking - Peak Capacity Without the Temp-Labor Risk

Volume fluctuation is the core of the 3PL business. The traditional answer - 30 to 50 percent additional temp labor in peak season - is expensive, hard to organize, and quality-sensitive.

NEO breaks this trade-off through collaborative picking: robots and human pickers operate in the same warehouse and the same picking cycle. You size the robot fleet for the baseline load of your client mix - and add human pickers alongside the robots when seasonal demand spikes.

The result:

  • No second, separate manual workflow that has to be ramped up every season
  • Less exposure to a tight temp-labor market
  • Pay-per-pick carries it commercially: more picks in peak = more robot capacity, with no hardware to buy or lease
  • Shorter onboarding for seasonal staff: they pick at the same station, in the same workflow your permanent team uses

For 3PL operators, this is often the strongest argument: you automate the baseline and keep the operational flexibility to scale with people during peaks - without rebuilding your workflow setup every season.

How NEO Works in a 3PL Environment

1

Assessment and Pilot Planning

NEO evaluates your warehouse - aisle widths, shelf heights, SKU profile, and picking volume. Together, we define a pilot zone covering one or more of your 3PL clients.

2

Installation During Ongoing Operations

The NEO:runner robots and the picking station are installed in your existing shelving. No reconstruction, no downtime. Other warehouse areas and clients remain unaffected.

3

Go-Live and Pilot Operation

After 6-8 weeks, you start automated operations. Pickers work at the station, robots bring bins from the shelves - up to 400 picks per hour.

4

Scaling on Demand

Once the pilot proves out, you scale to additional warehouse areas and clients. Additional stations and robots are added without disrupting ongoing operations.

What 3PL warehouses achieve with NEO

400picks/h
Picks per hour
1 → 3
Systems scaled
0
Upfront investment
70%
Less picking labor
Frank Hammermeister
No other provider combines such a simple automation solution with higher storage density like NEO. We see great potential to significantly support our fulfillment strategy with NEO.
Frank Hammermeister
CEO, Versandmanufaktur GmbH (GLS Group)

NEO runs in parallel with manual picking: robots and PickStations cover the automated portion, while staff continue to pick by order or by client manually. You control the share of automated picks per client segment.

The pilot-first approach was decisive: Versandmanufaktur could validate the concept with manageable risk before investing in scale - exactly the approach that makes sense in the 3PL business.

Read the full case study →

Technical Requirements

Check whether your 3PL warehouse meets the minimum technical requirements for NEO:
Shelving system Standard shelf-based racking No special shelving required
Aisle width Minimum 85 cm
Shelf height Up to 250 cm
Item dimensions Max 380 × 270 × 140 mm L × W × H
Item weight Max 5 kg
Pick volume 5,000+ picks/day recommended
Floor Level, load-bearing warehouse floor
WiFi Full WiFi coverage in the warehouse area

NEO is ideal for 3PL operators who:

  • Run multi-client fulfillment in existing shelf-based warehouses
  • Want to match fluctuating volumes with variable costs
  • Need to onboard new clients quickly with automated capacity
  • Want to reduce temp labor in picking operations

Not the best fit for:

  • Pure pallet warehouses without shelf-based racking
  • Items that exceed the size or weight limits
  • Warehouses with fewer than 5,000 picks per day
  • Sites planning a complete new-build with a shuttle system

Frequently Asked Questions

Is NEO suitable for multi-client fulfillment?

Yes. NEO:os manages SKU data and orders on a per-tenant basis. You can serve multiple 3PL clients through the same system - with separated order management and separate performance tracking per tenant.

How flexible is scaling with volume fluctuations?

Very flexible - through collaborative picking. Robots and human pickers operate in the same picking cycle. You size the robot fleet for the baseline load and add human pickers alongside the robots when seasonal demand spikes - no separate manual workflow to staff up. With the pay-per-pick model, you only pay for picks actually completed. When volume drops, your costs decrease proportionally - no fixed-cost block. Learn more about pay-per-pick

Can I install NEO alongside ongoing operations?

Yes. Installation takes place in the existing warehouse without operational downtime. Other client areas and manual processes continue undisturbed during setup. This is particularly relevant for 3PL operators serving multiple clients in one facility.

How does pay-per-pick fit 3PL contract models?

Pay-per-pick ties automation cost directly to fulfillment volume. If you bill your clients per order or per shipment, picking costs follow the same logic. There is no CapEx line item that you need to amortize across multiple client contracts - costs flow as OpEx directly into your client pricing. Learn more about pay-per-pick

Request a Fit-Check

Find out in a 30-minute call how NEO fits your 3PL warehouse - with a concrete assessment of pick volume, scaling, and cost. Or start with an overview of the NEO platform.

Request a Fit-Check