The Thalia Bücher GmbH, a leading omnichannel bookseller in German-speaking regions, has commissioned system integrator Element Logic to undertake an extensive automation project for its Thalia omnichannel hub in Marl. In addition to comprehensive conveyor systems and material handling equipment, Element Logic will install Germany’s largest AutoStore system, featuring 280,000 bins and 530 robots.

With expertise gained from more than 400 completed installations, Element Logic has been awarded the role of general contractor by Thalia to automate intralogistics at the Marl mega-facility. Located in the newly developed industrial area gate.ruhr, the project will be executed in two phases. In the first phase, Element Logic will install the AutoStore system with 280,000 bin storage locations and a comprehensive conveyor system in the omnichannel hub. Upon completion, 530 R5 robots will handle five-digit volumes of bins per hour across 69 connected picking ports.

Order fulfillment for both B2C and B2B will take place in two picking zones integrated into the system as “tunnels.” Supported by Element Logic’s AutoLight system, picks at the ports will deliver into up to four destination bins. In the AutoStore section dedicated to inbound goods, small and large batches will be stocked via an additional 27 ports. Packaging will be partially automated and completed by automatic packaging machines. A multi-kilometer conveyor network, managed by Element Logic, will connect the AutoStore system with the fast-moving goods zone, packing area, and shipping area.

Spanning more than 50,000 square meters, this facility will become Germany’s largest AutoStore system. Element Logic is responsible as the general contractor for intralogistics. The first phase of the project is slated to become operational in early 2026.

Key Figures at a Glance

• 280,000 bin storage locations
• 530 AutoStore robots
• 69 connected picking ports
• 27 inbound ports
• Tens of thousands of bins per hour (throughput estimate is 13,000 totes per hour) (200 TPH per port)
• 50,000+ m² facility size
• Go-live: Early 2026