SEMI-AUTOMATED ORDER-PICKING

Dexion Batch&Pick

An integrated solution that combines shelving systems, identification hardware, batch‑picking logic and TCPlus into a guided picking process.

Future-proof Stay flexible

Scalable Grow with us

Process Focus Clearly managed

WHY BATCH&PICK?

Moving Beyond Shelving. Focusing on Picking Performance.

In manual warehouses, picking costs are driven by walking distances, search time and picking errors. Dexion Batch&Pick addresses these cost drivers by treating shelving, hardware, software and process logic as one system.

Up to 60%

less walking time

Up to 98%

fewer picking errors

Up to 50%

lower picking costs

Key picking KPIs at a glance

When orders are picked individually, time and accuracy suffer. With Dexion Batch&Pick, measurable performance improvements can be achieved.

Multiple orders per picking cycle

Batch picking allows several orders to be processed simultaneously.

Higher productivity in existing warehouses

Performance gains without automation or building modifications.

POSITIONING

A Bridge Between Manual and Semi‑Automated Warehousing

For warehouse operations upgrading existing shelving or planning new installations with a focus on efficient, digitally supported picking.

Dexion Batch&Pick

Dexion Batch&Pick is suitable both for upgrading existing shelving layouts and for new shelving installations where batch picking and digital process control are defined from the start.

Dexion Batch&Pick is designed both for upgrading existing shelving environments and for new shelving installations where digital, batch‑based picking is planned from the outset. It transforms conventional person‑to‑goods operations by combining shelving systems, identification technology, TCPlus WMS and batch‑picking logic into a guided, scalable picking solution.

The modular structure allows step‑by‑step implementation based on operational needs. Additional elements, such as a work assist vehicle or man‑up lift, can be integrated where required to improve walking distances, ergonomics and overall picking performance.

Bridge technology Existing shelving & new installations Modular system design Manual to semi‑automated

"Dexion Batch&Pick allows warehouses to protect existing investments while systematically improving efficiency, accuracy and process control."

Daniel Düringer

Manager, Dexion Service Center

Dexion GmbH, Germany

BUSINESS IMPACT

Where Dexion Batch&Pick Creates Value

Typical environments and situations where targeted upgrades deliver measurable impact.

Existing shelving operations

Warehouses with installed shelving systems where manual picking works, but efficiency and accuracy are increasingly under pressure.

Operations facing new requirements

Growing order volumes, higher service levels or more goods require structured, digitally supported picking processes.

Step‑by‑step modernisation

Operations that want to improve performance through modular upgrades instead of full automation projects.

New warehouses with partial automation

Projects where flexibility, ROI and scalability make batch‑picking a suitable alternative to full automation.

Batch Picking Explained

In batch picking, several orders are grouped together into one picking batch. The picker passes through the shelving system once, picks items for multiple orders at the same time and assigns them correctly using visual guidance. Compared to single‑order picking, batch picking reduces walking distances, increases picks per hour and significantly improves accuracy.

Fewer picking errors.
Lower picking cost per order.
Performance upgrade for existing warehouses.

CHALLENGES

Where Costs Occur in Person‑to‑Goods Picking

Dexion Batch&Pick focuses on eliminating these inefficiencies.

Excessive travel time in manual picking

Walking and searching often account for the largest share of picking time.

Single‑order workflows

Picking one order after another increases travel time per order.

Lack of process guidance

Without visual confirmation, picking errors and follow‑up work increase.

Picking errors driving claim costs

Lack of process guidance and verification increases mispicks, returns and downstream handling costs.

CUSTOMER STORY

Project Spotlight

Hi280 shelving combined with a work assist vehicle enables efficient person‑to‑goods picking across multiple shelf levels.

Modernising picking performance with shelving and a work assist vehicle

Improving efficiency and ergonomics in manual picking environments through targeted upgrades

This project demonstrates how existing shelving environments can be modernised without a full automation approach. By combining Hi280 shelving systems with a work assist vehicle, vertical order picking was integrated directly into daily operations. The solution reduced walking time by allowing operators to pick across multiple shelf levels in one continuous movement, while improving ergonomics and process stability. Instead of replacing the existing infrastructure, targeted upgrades were introduced to increase performance and prepare the operation for future optimisation steps. The use case reflects the core principle behind Dexion Batch&Pick: enhancing manual picking environments through modular components, guided processes and scalable upgrades that deliver measurable improvements with controlled investment.

Read case study

DEXION BATCH&PICK COMPONENTS

One Solution. Multiple Coordinated Components.

Each element is proven on its own. Integrated, they deliver efficiency, operational control and compliance with safety and regulatory requirements.

Shelving systems

Flexible shelving such as Hi280 provides the physical basis for structured storage of small parts, cartons and containers.

Work Assist Vehicle / Man‑Up Lift

A man‑up lift enables vertical order picking directly at the shelving system. Driving and lifting are combined in one movement. This reduces walking time in person‑to‑goods picking.

Identification & display hardware

Wireless pick‑to‑light displays guide the picker and allow direct confirmation and quantity correction.

Batch‑picking logic

Orders are grouped and processed in parallel, reducing travel time and increasing throughput.

TCPlus Warehouse Management System

TCPlus controls orders, batches, inventory and device integration in real time.

One end‑to‑end solution

One integrated batch‑picking solution from a single source, including system components and associated services.

BATCH-PICKING HARDWARE

Hardware Required for Batch Picking

Efficient batch picking requires reliable communication between software and display devices.

Designed to guide picks. Built to reduce effort.

Hardware for batch picking visually organizes the picking process, reduces manual errors, and supports efficient person-to-goods workflows.

Guided picking at the point of action
Parallel order handling
Reduced manual errors through confirmation
Flexible deployment in existing layouts
Process readiness for scaling

PICK-BY-LIGHT SOLUTION

Wireless Pick‑by‑Light Infrastructure

Designed for flexibility and guided confirmation.

Handheld scanners are used to identify items and confirm pick actions within the batch‑picking process.
They enable fast, reliable verification of articles and orders.
This supports accurate picking and seamless integration with TCPlus‑controlled workflows.

Central communication unitconnecting TCPlus with up to 200 wireless display units via 2.4 GHz WiFi.

Battery‑powered display units with quantity indication, confirmation and correction buttons. Flexible mounting on shelves, trolleys or containers

Scanners and labelling systems can be integrated into TCPlus as required.

WORKFLOW & PROCESS

How Dexion Batch&Pick Works in Daily Operation

A guided process starting in the software and ending with confirmed picks. Paperless. Guided. Traceable.

1. Order selection

Orders are selected and grouped into a batch in TCPlus.

2. Batch logic

TCPlus defines the picking order to minimise travel time.

3. Visual guidance

Pick‑to‑light displays show quantities and target orders.

4. Confirmation

Each pick is confirmed directly at the display or via scanning.

5. Inventory update

Stock levels and order status are updated in real time.

6. Data-driven purchasing & reporting

Order, pick and inventory data create a reliable basis for purchasing decisions, forecasting and continuous process improvement.

CONNECTING THE BUILDING BLOCKS

Making Shelving Intelligent – Step by Step

Connecting shelving, software and picking technology to turn manual storage into a guided, digital picking process.

Shelving systems provide the structured storage base for small parts, cartons and containers.
In Dexion Batch&Pick, existing shelving remains in place and becomes the backbone for digitally guided picking processes instead of being replaced.

TCPlus connects orders, inventory and batch‑picking logic into one central system.
It adds transparency, process control and real‑time feedback, forming the bridge from manual handling to digitally supported warehouse operations.

A work assist vehicle or man‑up lift enables efficient person‑to‑goods picking across multiple shelf levels.
By reducing walking time and improving ergonomics, it accelerates order picking where vertical access is required.

AVAILABILITY

Service & Aftersales for Batch&Pick Solutions

Dexion Batch&Pick is supported by structured service offerings that protect existing shelving infrastructure, ensure system availability and enable continuous performance improvements over time.

Shelving systems – inspection & lifecycle services

Ensure safety, compliance and long‑term usability of existing shelving systems
Rack inspections, condition assessments, documentation and retrofit recommendations
Supports safe operation and protects existing warehouse infrastructure
Basis for targeted retrofits and batch‑picking integration
Extends service life of shelving systems and reduces operational risk

TCPlus WMS – support & remote services

Stable operation of batch‑picking and digital warehouse processes
Software support, system updates, configuration assistance and troubleshooting
Remote diagnostics, support and assistance for daily operations
Ongoing support for identification hardware and batch‑picking logic
Supports functional extensions and step‑by‑step system upgrades

Operational support & optimisation

Maintain performance and adapt the system to changing requirements
Operator training, process optimisation and system fine‑tuning
Modular expansion without interrupting live operations
Continuous efficiency improvements instead of one‑time projects

FAQ

Frequently Asked Questions

Clear answers for decision‑makers.

What is Dexion Batch&Pick?

An integrated picking solution combining shelving, batch‑picking hardware, TCPlus WMS and optimised process logic.

What does batch picking mean in practice?

Several orders are picked in one cycle with guided and confirmed item allocation.

Which hardware is required?

Wireless pick‑to‑light displays, a coordinator and a system controller, optionally scanners and labelling.

What is the role of TCPlus?

TCPlus controls orders, batches, inventory and device communication in real time.

Can this be implemented in existing warehouses?

Yes. Dexion Batch&Pick is designed for retrofits as well as new installations.

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