R Prahalad, Chief Business Officer, Virya Autonomous Technologies.

What is the current status of automation in material handling and intralogistics operations in the industry today?

The landscape of intralogistics and material handling is undergoing a significant transformation in recent years, driven by advancements in automation technologies, sustainability initiatives, and evolving market demands. From smart warehouses to autonomous mobile robots, technology has played a pivotal role in driving efficiency and reliability. As we mature in this arena, customer expectations move towards the idealistic conditions irrespective of challenging operational environments. Thus, as more people adopt these technologies, the more they will mature.

Today, automation in material handling and intralogistics is not only a growing trend but a strategic imperative for businesses aiming to stay competitive, efficient, and resilient in a dynamic global supply chain ecosystem.

In industries like automotive, e-commerce, and pharmaceuticals, technological products like AGVs, AMRs, and AS/RS are becoming standard. Sectors such as FMCG and apparel are gradually transitioning, often starting with semi-automated setups due to cost and integration challenges. Mobile robotics, particularly AMRs, are gaining popularity for their flexibility and ease of deployment. Many companies are integrating AI, IoT, and analytics to enhance real-time decision-making and operational efficiency. Instead of building new facilities, retrofitting existing warehouses with modular automation is a growing trend. Most operations today follow a hybrid model, combining automated systems with human labour for scalability and adaptability.

Top Emerging Products and Technologies in material mobility include:

1. Mobile Robots & Autonomous Systems: Over 70% of robots deployed last year were for logistics, primarily aiding material transport and picking, with Asia-Pacific leading adoption.

2. Artificial Intelligence & Machine Learning: AI and ML are used for predictive maintenance, demand forecasting, and optimizing warehouse workflows.

3. Internet of Things (IoT): IoT enables real-time tracking and monitoring of goods, improving visibility and operational control.

4. Robotics & Automation: Robots are increasingly used for sorting, picking, and palletizing, while cobots and  AR assist humans in complex tasks.

5. Data-Driven Operations & Digital Transformation: Predictive analytics, digital twins, and cloud-based WMS are reshaping intralogistics with real-time insights and smarter planning. 

What are the key challenges companies are currently facing in warehousing and logistics?

With the existing traditional model, companies are facing challenges in scalability due to labour shortages, space optimisation, system integration, inventory inaccuracy, order fulfilment delays and inconsistent quality and human error.

By adopting Industry 4.0, these challenges can be overcome significantly. However, today organisations face headwinds in adopting these emerging technologies due to several factors like high upfront costs, brownfield automation, skill gaps, limited flexibility, cybersecurity risks, maintenance dependency, employee resistance and expectations of a quick RoI.

Industry 4.0 needs to be strategised at management level with long term objectives. The stakeholders in the organisation will need to be sensitised to a discovery phase, deployment phase and maturity phase in the implementation.  The partner selection process cannot be merelyon costs, but on technology, capability and – more importantly – alignment with the organisation’s automation requirements. 

How has the post-pandemic era changed customer expectations around warehousing and last-mile logistics?

The Covid-19 pandemic dramatically reshaped consumer behaviours and expectations. There is now a heightened demand on automation. In the e-commerce sector – faster deliveries, real-time order tracking, error-free fulfilment, flexible returns and timely customer issue resolutions are becoming the drivers. Backend data analytics to springboard the business is emerging as a very strong requirement.

In the in-factory material movement space, there is a vision to reduce/repurpose people  deployed on mundane tasks. For example, all manual material ‘push-pull’ activities both inside and outside the shopfloor are being automated through AMRs. In India, established platforms like those from the Maini Group are known for their reliability and seamless integration with factory ecosystems.

What are the top emerging technologies or innovations that will shape the future of material handling and warehousing? How is the role of AI and data analytics evolving in this space?

Future innovations will build on today’s foundations to further improve efficiency and reduce manual intervention. These include:

• Digital twins for simulating and optimising workflows

• 5G for low-latency connectivity

• Blockchain for traceability and trust in supply chains

• AI-driven predictive maintenance to reduce downtime, and

• Low-cost Sensors to improve affordability and coverage.

Data analytics and AI will become central to forecasting, optimisation, and autonomous decision-making – playing a strategic role across all operational layers.

What progress can one expect towards fully autonomous warehouses or ‘dark warehouses’?

The long-term aspiration across industries is to move toward “dark” warehouses – fully automated, human-free environments. While this vision remains aspirational today due to high costs and multiple unknowns, incremental steps are already underway. With continued innovation and scale, dark warehouses may become viable at a broader scale in the coming decade.

Summing up, automation in material handling and intralogistics is no longer optional but essential for staying competitive. As companies navigate labour shortages, rising costs, and increasing customer expectations, the adoption of mature technologies and exploration of emerging ones will determine their success. The future points toward smart, adaptive, and potentially fully autonomous operations where data and AI drive continuous improvement. For those ready to innovate and invest, the opportunities are immense.

(The views expressed in interviews are personal, not necessarily of the organisations represented.)

Wg Cdr R Prahalad (Retd) is the Chief Business Officer at Virya Autonomous Technologies, a Maini Group company. He is currently focussing on autonomous material mobility solutions to industries, ensuring seamless integration with factory ecosystems apart from in-campus people mobility and learning and development through Industry-Academia partnerships. During his decade-long tenure with the Maini Group, he has developed several smart and connected electrically operated Ground Support Equipment for military and civil aviation applications. In his previous role with the Indian Air Force, spanning over two decades, he has held key positions as Chief Engineering Officer and Commanding Officer of operational units.