Pick and pack Ocado systems have become famous across the globe for one reason: they’re incredibly fast, automated, and shockingly accurate. While most fulfillment centres rely heavily on manual labour, Ocado’s approach blends robotics, AI, and lightning-fast grid technology to handle thousands of orders a day with minimal errors.
If you’ve ever wondered how Ocado manages to deliver fresh groceries so quickly while keeping items organised, safe, and perfectly packed, this guide breaks down exactly how their system works and what lessons modern warehouses can take from it.
What Is the Pick and Pack Ocado System?
The pick and pack Ocado process is an automated fulfilment model powered by robots operating on a 3D grid system. Instead of humans walking to shelves, robots travel on top of a grid structure retrieving totes stored below. These totes hold different grocery products, which are then transported to pick stations.
Key components of the Ocado system include:
• High-speed robots
• A modular fulfillment grid
• AI-driven inventory management
• Automated packing stations
• Real-time order routing
• Temperature-controlled storage zones
This setup produces extremely high fulfilment throughput compared to traditional warehouse models.
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How the Pick and Pack Ocado Workflow Actually Works
The genius of the Ocado system lies in how everything moves seamlessly and continuously. Here’s the simplified workflow:
1. Orders Come In
When a customer places an order, Ocad’s system instantly begins organising a picking plan.
2. Robots Retrieve Goods
Hundreds of robots glide across a giant steel grid, fetching storage bins containing the needed products.
3. Items Move to Pick Stations
Totes arrive at human or robotic pickers. Workers don’t walk items come to them.
4. Products Are Scanned and Verified
Quality checks ensure freshness, expiry date accuracy, and correct quantities.
5. Packing and Bagging
Items are placed into Ocado-approved bags and crates. This is often semi-automated.
6. Temperature-Zoned Storage
Orders are separated into frozen, chilled, and ambient sections to preserve freshness.
7. Dispatch and Real-Time Routing
Orders move to vans operating on optimal delivery routes.
Why the Pick and Pack Ocado System Is So Efficient
Businesses love analysing Ocado’s workflow because it solves many common warehouse challenges. Here’s what makes it extraordinary:
• Robots reduce travel time to nearly zero
• AI predicts product demand
• Dense storage improves warehouse space efficiency
• Automated routing shortens fulfilment time
• Very low error rates
• Ideal for high-volume grocery orders
It’s no exaggeration to say Ocado set a global benchmark for logistics automation.
Technologies Behind Pick and Pack Ocado
Ocado uses some of the most advanced technologies in the fulfillment world:
• Robotics for bin retrieval
• Machine learning for forecasting demand
• Digital twins for simulating real-world warehouse operations
• IoT-enabled sensors for monitoring products
• Ocado Smart Platform (OSP) for global operations
This helps them maintain exceptional accuracy, efficiency, and scalability.
Lessons Businesses Can Learn from the Pick and Pack Ocado Method
Not every warehouse can install a robotic grid system but plenty of Ocado’s principles can be applied anywhere:
Use the Right Packaging
Protection, visibility, and durability matter.
Explore Carewell packaging options:
https://carewellgroup.com.au/product-category/packaging/
Improve Picking Speed
Even simple tools like scanning equipment and product-specific trays reduce time loss.
Warehouse tools:
https://carewellgroup.com.au/product-category/tools-equipments/
Prioritise Safety Gear
Fast-moving operations need protective equipment, including:
https://carewellgroup.com.au/gloves/
https://carewellgroup.com.au/product-category/safety-vests/
Optimise Warehouse Layout
Shorter travel routes equal higher throughput.
Temperature-Zone Organisation
Especially vital for food, cosmetics, chemicals, and pharma.
Use Better Packing Materials
Examples:
• Poly mailers – https://carewellgroup.com.au/product-category/poly-bags-mailers/
• Stretch wraps – https://carewellgroup.com.au/product-category/wraps/
• Tapes – https://carewellgroup.com.au/category/tapes/
The Future of Pick and Pack: Following Ocado’s Footsteps
The next generation of warehouses will likely include:
• Full robotic picking
• Automated driverless forklifts
• Predictive packaging
• AI-managed inventory
• Smarter 3PL integrations
Carewell Group stays ahead by supporting businesses with essential packaging, safety gear, and scalable logistics solutions.
Explore custom solutions:
https://carewellgroup.com.au/custom-solutions/
Carewell Group Pty Ltd
Unit 27/191, Mccredie Road, Smithfield, NSW 2164
Phone
+61 0477 123 699
Emails
sales@carewellgroup.com.au
info@carewellgroup.com.au
logistics@carewellgroup.com.au
