Knapp OSR Shuttle Evo: Revolutionizing Warehouse Automation in 2025

The logistics and warehousing industry is evolving at an unprecedented pace, driven by the demand for efficiency, scalability, and adaptability. Enter the Knapp OSR Shuttle Evo, a cutting-edge automated storage and retrieval system (ASRS) designed to meet these modern challenges head-on. Developed by Knapp, a global leader in warehouse automation, this shuttle system has become a benchmark in the industry, offering unparalleled flexibility and performance. In this blog post, we’ll explore what makes the OSR Shuttle Evo a game-changer, its key features, real-world applications, and why it’s a must-have for businesses in 2025.

The Knapp OSR Shuttle Evo is an advanced shuttle-based storage system that optimizes warehouse operations by automating the storage, retrieval, buffering, and sequencing of goods. Unlike traditional warehousing solutions, this system uses intelligent shuttle robots to handle a variety of storage units—containers, trays, and cartons—making it a versatile choice for industries ranging from e-commerce to food retail. Launched as an evolution of Knapp’s earlier shuttle technologies, the OSR Shuttle Evo combines high-density storage with scalable performance, setting new standards in logistics automation.

A Brief History of Knapp’s Shuttle Technology

Knapp pioneered shuttle technology in 2002 with the first OSR Shuttle system installed at Richter Pharma AG in Austria. Since then, the company has refined its offerings, culminating in the OSR Shuttle Evo, which debuted at LogiMAT 2018. With over 600 installations worldwide, Knapp has solidified its position as a leader in this space, continuously adapting to the needs of modern supply chains.

Why It Matters in 2025

As of April 2025, the rise of omnichannel distribution, micro-fulfillment centers, and sustainability goals has made efficient warehouse automation more critical than ever. The OSR Shuttle Evo addresses these trends by offering a system that’s not only fast and reliable but also adaptable to fluctuating demands—perfect for businesses aiming to stay competitive in a dynamic market.

Key Features of the OSR Shuttle Evo

The OSR Shuttle Evo stands out due to its innovative design and robust capabilities. Here’s a closer look at what makes it tick:

Scalability and Flexibility

One of the standout features is its scalability. The system can reach heights of up to 30 meters and allows businesses to expand storage capacity or performance independently. Whether you need more shuttles, aisles, or lifts, the OSR Shuttle Evo adapts seamlessly to growing needs without disrupting operations.

High-Density Storage

With double-deep or multi-depth storage options, the system maximizes space utilization. This is a boon for warehouses with limited floor space, as it can store both active stock and buffer inventory in a single setup, reducing the need for multiple facilities.

Intelligent Shuttle Robots

The heart of the system lies in its shuttle robots, which move lengthwise and crosswise within racks, accessing every storage location efficiently. Variants like the 1D (one shuttle per level) and 2D (shuttles that switch aisles) offer tailored performance for different workflows.

KiSoft Software Integration

Powered by Knapp’s KiSoft software, the OSR Shuttle Evo ensures seamless coordination between hardware and operations. This intelligent platform manages order fulfillment, stock levels, and shuttle movements, providing real-time insights for optimized performance.

Extreme Temperature Resilience

Capable of operating in temperatures as low as -28°C, the system is ideal for cold chain logistics, such as frozen food storage. This durability makes it a favorite in industries where maintaining product integrity is non-negotiable.

• Scalable Design: Add shuttles or racks as needed.
• Space Efficiency: High-density storage up to 30 meters.
• Versatile Handling: Works with containers, trays, and cartons.
• Smart Software: KiSoft enhances operational control.
• Cold Chain Ready: Functions in sub-zero environments.

Real-World Applications of the OSR Shuttle Evo

The OSR Shuttle Evo isn’t just a theoretical marvel—it’s transforming warehouses across the globe. Let’s explore some notable use cases.

E-Commerce and Omnichannel Fulfillment

Companies like Luxottica and Arvato have deployed the OSR Shuttle Evo to handle the complexities of omnichannel distribution. For instance, Arvato’s cosmetics warehouse uses a 2D shuttle system capable of processing 12,500 containers per hour, flattening demand peaks and ensuring fast delivery.

Food Retail and Cold Storage

Shufersal, an Israeli grocery chain, relies on the system for its frozen goods warehouse, operating at -24°C. The OSR Shuttle Evo automates heavy lifting in harsh conditions, improving worker safety and efficiency while maintaining the cold chain.

Electronics and Wholesale

Schukat Electronic in Germany redesigned its distribution processes with the OSR Shuttle Evo, scaling from 64,000 to 140,000 storage locations. This flexibility supports their growing catalog of 35,000 electronic components, ensuring rapid order processing.

Agricultural Supply Chains

Kramp, a leading agricultural spare parts supplier, uses the system at its Varsseveld headquarters. With 134,400 storage locations and 120 shuttles, it handles over 200,000 products, delivering overnight to customers across Europe.

Company	Industry	Key Benefit
Arvato	Cosmetics	High throughput (12,500 containers/hour)
Shufersal	Food Retail	Cold storage at -24°C
Schukat Electronic	Electronics	Scalable capacity (up to 140,000 locations)
Kramp	Agriculture	Overnight delivery for 200,000+ products

Benefits of Implementing the OSR Shuttle Evo

Adopting the OSR Shuttle Evo offers tangible advantages for businesses looking to streamline operations. Here’s why it’s worth the investment:

Increased Efficiency

The system’s ability to handle multiple processes—storing, retrieving, buffering, and sequencing—in one setup reduces manual labor and speeds up workflows. Goods-to-person workstations further boost picking rates, cutting order fulfillment times.

Cost Savings

By optimizing space and reducing the need for additional facilities, the OSR Shuttle Evo lowers operational costs. Its energy-efficient shuttles also minimize power consumption, aligning with sustainability goals.

Enhanced Adaptability

Businesses can scale performance or storage independently, making it easy to respond to seasonal spikes or long-term growth. This adaptability ensures a future-proof investment.

Improved Worker Safety

In cold storage or high-volume environments, automation reduces physical strain on employees. For example, Shufersal’s staff no longer face the grueling task of manually handling frozen goods at sub-zero temperatures.

• Faster Operations: Streamlined picking and retrieval.
• Lower Costs: Reduced space and energy expenses.
• Future-Ready: Scales with business growth.
• Safer Workplaces: Less manual labor in tough conditions.

Why Choose the OSR Shuttle Evo in 2025?

As warehouses evolve to meet the demands of a fast-paced, tech-driven world, the OSR Shuttle Evo emerges as a top contender. Its blend of scalability, efficiency, and resilience makes it ideal for businesses navigating the complexities of modern logistics.

Meeting Today’s Challenges

With e-commerce booming and customers expecting next-day delivery, warehouses need systems that can keep up. The OSR Shuttle Evo’s high throughput and omnichannel capabilities ensure businesses stay ahead of the curve.

Sustainability and Innovation

Knapp’s focus on energy-efficient design and modular scalability aligns with 2025’s push for greener operations. The system reduces waste and supports sustainable growth, appealing to eco-conscious companies.

Competitive Edge

In a crowded market, staying competitive means leveraging the best tools. The OSR Shuttle Evo’s proven track record—over 60,000 shuttles in operation globally—offers reliability and performance that competitors struggle to match.

Ready to transform your warehouse? The Knapp OSR Shuttle Evo isn’t just a tool—it’s a strategic asset for 2025 and beyond. Whether you’re in retail, manufacturing, or logistics, this system delivers the efficiency and flexibility needed to thrive in today’s economy.