Package Handling
DCS’s design and engineering team has more than 40 years of experience creating unique parcel handling systems for diverse customer applications. With installations including semi-automated handling in small city distribution centers and fully automated, integrated hubs with advanced conveyor and sorter equipment, DCS routinely thinks outside the box.
E-Commerce and Multi-Channel Fulfillment
DCS designs and implements end-to-end warehouse automation solutions for e-commerce and multi-channel retailers that address numerous workflow challenges. This includes solutions for receiving, putaway, storage, replenishment, order fulfillment, picking, packing, sortation, and outbound shipping. Our custom integrated warehouse, distribution, and fulfillment systems draw from a deep pool of conventional, semi-automated, and automated material handling technologies.
Various Distribution Applications
Whether an operation is considering the construction of a new distribution or fulfillment center, or a retrofit or expansion of an existing facility, it’s important to create a solution that fits the overarching supply chain strategy. DCS has four decades of experience designing and integrating comprehensive, end-to-end material handling solutions that meet a multitude of operational goals. Whether conventional, semi-automated, or fully automated, DCS can help your organization implement a custom solution that meets its goals while maximizing return on investment (ROI).
Supply Chain Consulting
The DCS Supply Chain Consulting team offers a range of services to help your operations address the challenges it faces. Working in partnership with you, DCS consultants analyze your business data- existing workforce, workflow processes, inventory, order data, operations, and more- to determine a strategy that addresses your unique needs. Whether you need an operations assessment, process improvement recommendations, or distribution design services, DCS consultants will help guide you to the material handling system or operational solution that best meets your current and future needs, as well as your budget.
Customer Support
Keeping your warehouse operations and material handling systems running smoothly and at the peak of productivity are the goals of DCS’ Customer Service Team. By partnering with DCS, your warehouse automation solution is supported from commissioning to end of life. You’ll receive comprehensive in-house training of your personnel, including specialized training of your designated internal system expert. Plus, DCS offers a complete package of spare parts and expert system troubleshooting support from qualified engineers dedicated to your installation.
System Design & Integration
DCS offers a broad range of material handling equipment and automated system design, installation, and integration services for a multitude of projects. These include retrofits, expansions, upgrades, and more. While every project is unique, our system design and execution processes are the same, encompassing meticulous attention to detail, frequent communication, and a dedicated partnership with our clients.
About Us
Designed Conveyor Systems (DCS) has 40 years of experience serving major clients in multiple industries by providing material handling, full-scale warehouse operations, and conveyor design solutions that are custom crafted for their needs. DCS does not sell ready-made conveyor systems but builds relationships that empower collaboration to craft custom warehouse designs together. DCS utilizes consulting, engineering design, project management, installation services, and client support to ensure our customers can keep their promises to deliver on time.
With more than 40 years of experience providing automated system design, installation, and integration services, DCS has created solutions for companies throughout the United States in a broad range of industries and markets. We’ve completed more than 1500 projects ranging from greenfield facilities with completely new systems to expansions and retrofits of existing operations.

So… What About Warehouse Automation?

White Robot to illustrate warehouse automation and the technology Designed Conveyor Systems offers for Operations Materials and Design.

Warehouse Automation


Recently, you’ve felt the increasing demands. More complicated orders. Exacting customer expectations. Rising prices of land and labor.


Perhaps you’ve considered warehouse automation, but the price tags on those massive, complicated systems have scared you away.


Warehouse owners across the United States are turning to automation. As stated in a white paper by Westernacher Consulting, Automation has gained increasing traction over the last few yearsu2026 A recent study by PRG shows that over 10% of warehouses in the U.S. were using sophisticated automation technologies in 2016: a trend that is likely to accelerate in the next five years.


Yes, those lights out warehouses (automation so powerful it can operate without humans present) are expensive, but there are actually four different levels of warehouse automation. This post breaks down each level and weighs the pros and cons of increased warehouse automation.



The Four Levels of Warehouse Automation

Low Automation:

  1. Description: These warehouses use paper systems and most decisions are made by warehouse workers. These employees decide where to place items with some help from a printed system. This means that workers have to do a lot of walking and that more human errors may occur.
  2. Cost: Cost of Doing Business
  3. ROI: Operating Profits

System Automation:

  1. Description: Westernacher Consulting gives this summary, Here, a Warehouse Management System (WMS) is used to make decisions on where to put away/pick items and manage processes such as de-consolidation, VAS (Value Added Services) and quality inspection. It also optimizes decisions on when to perform the tasks, and who should perform the tasks. According to Westernacher Consulting, such systems generally have higher productivity than low automation systems. They also use space more efficiently.
  2. Cost: $500,000 to $2,000,000
  3. ROI: 6 months to 2 years

Mechanized Automation:

  1. Description: These systems actually help transport the products instead of workers having to carry everything. These often involve conveyor belts or Automated Storage and Retrieval Systems (AS/RS). Both of these move products around for the workers, reducing the distance they have to walk and increasing warehouse efficiency.
  2. Cost: $5,000,000 to $15,000,000
  3. ROI: 2-4 years

Sophisticated Automation:

  1. Description: Westernacher Consulting describes these warehouse systems as, using highly automated equipment to eliminate manual movements and streamline order-picking processes. This level of automation requires systems to handle complex decision-making logic. These would be the lights off warehouses described earlier.
  2. Cost: $50,000,000+
  3. ROI: > 5 Years


Pros and Cons of Warehouse Automation




  • Fewer Mistakes: Machines don’t get tired or have bad days. They are less prone to mistakes than are humans. This also leads to increased safety, productivity, and accuracy, according to Conveyco.


  • More Efficient Use of Space: When switching from low automation to system automation, companies see space utilization improve by 10-20%, reported Westernacher Consulting.


  • Ease of Use: According to Viastore Systems, Because automated systems are engineered to support people as they go about their tasks, they are designed to be intuitive and easy to use. Training can even take less than 20 minutes, they said.
  • Save Money on Labor: Westernacher Consulting stated that, Today, the single largest expense for warehouse operation is labor. Just as bad, it’s harder than ever to attract workers.
  • Low Temperatures: You can buy machines that work at cold temperatures where people might have trouble working. The machines may require some modifications so make sure to ask.
  • Different Levels: As discussed in the previous section, there are different levels of automation with different prices that you can customize to fit your needs. Whether you want a slight upgrade or full automation, we’ll find something tailor-made for you.




An article by Conveyco lists cons including:


  • Expensive initial investment: The prices in the above section are expensive, but they should pay for themselves quickly.


  • Maintenance: Like all technology, some maintenance is necessary.


  • Not for Everyone: As reported in the article, AS/RS [Level 3 automation], like all automation technologies, are best suited for operations that have regular, predictable, and repetitive tasks. Operations that vary widely in terms of product or materials handled from week to week or month to month may find it difficult to make AS/RS fit into their business plan. Because AS/RS works according to preset systems, processes, and analysis, rapid change can be difficult to facilitate.


Automation is an invaluable tool for making your warehouse more efficient and effective. It can save you a lot of money over time. If you’re considering automating your warehouse, we’d love to talk to you.


A businesses warehouse is unique and needs a unique solution. That’s why the first thing we do is listen. DCS builds relationships, sharing ideas and working together with you. We involve you in the process, so the end result is custom-made for your warehouse. Don’t settle for a one-size fits all solution. With nearly 40 years of experience creating material handling solutions, we can help you. We specialize in warehouse design, operations, and automation. Let’s craft a solution together.