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Project: Robot Integration Costing Analysis

This project involved a comprehensive costing analysis comparing the use of cold rooms with mobile robotic arms for dark store operations to traditional methods using glass door refrigerators and manual labor. The study demonstrated substantial cost savings, improved energy efficiency, and labor reduction by implementing robotic systems, with an estimated ROI of 3 months.

Project Description

The aim of this project was to evaluate the economic viability of replacing traditional refrigeration and manual labor systems in dark stores with cold rooms and articulated robotic arms. By performing detailed cost analysis, the project calculated whole life costs (WLC) for both systems, considering initial setup, maintenance, and energy consumption. The study revealed that robotic systems could save approximately £1.84 million in upfront costs and reduce yearly energy expenses by 90%, alongside reducing labor costs by 50%.

Key Features

• Cost Efficiency: Demonstrated a £1.84 million upfront cost savings and reduced annual operational costs by £1 million per store using cold rooms and robotic arms.


• Energy Savings: Achieved a 90% reduction in energy usage by replacing glass door refrigerators with highly efficient cold rooms.


• Labor Reduction: Implemented a robotic system that reduced personnel requirements by 50%, contributing to a projected ROI in just 3 months.


• Sustainability: Lowered environmental impact, with recycling costs cut by £141,990 and potential for net-zero carbon emissions in the long term.

Technologies Used

• Articulated Robotic Arms: Utilised for automated picking and restocking in cold rooms, replacing manual labor.


• Cost Forecasting: Applied analogy, extrapolation, and engineering methodologies to calculate whole life costs and energy savings.


• Sustainability Analysis: Assessed environmental benefits, including reduced energy consumption and waste.


• Return on Investment (ROI) Calculation: Estimated ROI based on cost savings in labor, energy, and maintenance.

Project Gallery

Revevant images taken from the costing report:

3D render of FANUC CRX on a custom mobile pedestal, sold together on Vention.

Graph obtained from WLC Calculator.xlsx showing whole life cost differences between stores.

Clear linear WLC increase as store size increases, no benefit to larger store size.

WLC appears to follow a logarithmic increase, larger stores prove more efficient.

Full Costing Report

Below is a pdf of the full costing report, do give it a brief read if you are interested and have a moment: