Highlighting vital and viable solutions that are sometimes forgotten, and often overlooked.

When people think about warehouse automation today, the conversation usually jumps straight to the latest robotics, AI-driven systems, and advanced shuttle solutions. And rightly so — cutting-edge technology has revolutionized how we move, store, and manage goods.

Yet, according to Cary Spraggins, President of Streamline-It, not every effective automation tool needs to be the newest. Cary, an industry veteran known for delivering some of the most advanced systems on the market, has a deep respect for a category he fondly calls “forgotten automation.” These are tried-and-true systems that have been serving warehouses reliably for decades but are too often overlooked in the race for the next big thing.

In this series, we shine a spotlight on these time-tested solutions — systems that deserve a second look, not just for their historical value, but for the tangible advantages they still deliver today.

The Case for “Forgotten Automation”

Flashy marketing and rapid innovation cycles can sometimes overshadow solid, reliable technology that continues to solve core operational challenges. Cary coined the term “forgotten automation” to describe these workhorse solutions that quietly deliver high performance without the hype.

At Streamline-It, we believe there’s a lot to gain from balancing innovative new systems with proven legacy technologies, especially for companies looking to modernize thoughtfully and cost-effectively.

One prime example? Horizontal carousels.

Horizontal Carousels: Overlooked but Indispensable

Horizontal carousels may not grab headlines like drones or AI-powered robots, but they’ve been a staple in the automation toolbox for good reason.

These systems offer all the hallmark benefits you’d expect from modern warehouse automation:

• Dense Storage: Carousels make excellent use of floor space, enabling high-density storage within a compact footprint.
  
• High Efficiency: By bringing goods directly to the picker, horizontal carousels drastically reduce walk time and improve picking rates.
  
• Exceptional Accuracy: Automated retrieval minimizes human error, boosting order accuracy and customer satisfaction.
  
• Versatility: They support a wide variety of picking strategies and can adapt to changing product mixes.
  
• Scalability: Carousels can be easily integrated into larger systems or expanded as needs grow.
• Ergonomics: Reducing reach, bend and climb, improved employee ergonomics improves the bottom line from several angles.
• Inventory Management: Integrated inventory management systems allow for real-time tracking of stock levels, helping businesses better manage their inventory and avoid overstocking or stockouts.
  

A Vintage Advantage: Simplicity Meets Reliability

Beyond matching modern systems in performance, horizontal carousels also offer unique, old-school strengths that newer technologies sometimes lack.

• Simplicity: Horizontal carousels can be operated and maintained with basic tools and minimal specialized training. This ease of use makes them accessible and practical for teams of all sizes.
  
• Low Points of Failure: Fewer moving parts and simpler mechanics mean less downtime and fewer maintenance headaches compared to more complex systems.
  
• Proven Durability: Decades of use have vetted these machines thoroughly — unlike some newer technologies still proving their long-term reliability.
  
• Excellent in Older Facilities: Carousels thrive where newer high-bay systems struggle. For warehouses with low ceilings, odd layouts, or multi-story configurations, carousels can deliver automation benefits without costly building modifications.
  
• Resilient in Tough Conditions: They perform reliably even in freezer environments or other challenging conditions that can be tough on delicate, cutting-edge tech.
  

Boosting Productivity and Morale

One often overlooked benefit of these “forgotten” solutions is their impact on the workforce. Horizontal carousels do more than just improve productivity metrics — they can enhance the overall work experience.

By minimizing the physical strain of walking long distances and bending to pick items, carousels help employees work comfortably and efficiently. This ergonomic advantage translates into higher morale, lower turnover, and greater loyalty — factors that are increasingly important as labor shortages challenge the industry.

When “Old” is Exactly What You Need

At Streamline-It, we don’t just chase the latest technology for the sake of innovation. We design solutions that make sense for each unique facility and business goal. Sometimes, the best answer is the most advanced shuttle system on the market — but other times, a humble horizontal carousel is the perfect fit.

Cary Spraggins puts it simply: “These systems were engineered decades ago to solve the same core problems we face today — maximizing space, increasing throughput, and improving accuracy. That fundamental need hasn’t changed, and neither has their value.”

A Smarter Approach to Modernization

In the rush to automate, companies can easily overlook practical, proven options in favor of the latest trend. But ignoring “forgotten automation” means missing out on reliable, cost-effective solutions that could deliver impressive ROI with fewer headaches.

For operations housed in older buildings, dealing with ceiling height limitations, or facing budget constraints, these time-tested systems can be the bridge between manual processes and fully automated, high-tech systems.

Stay Tuned

In this series, we’ll continue to unpack other examples of “forgotten automation” that deserve a fresh look in your next project. From carousels to classic pick modules and beyond, we’ll show you how blending the best of old and new can drive your warehouse forward — without breaking the bank or overcomplicating your operations.

Ready to see what a smart mix of proven and cutting-edge solutions could do for your facility? The Streamline-It team is here to help you navigate every option and design a system that fits your space, your people, and your goals.

Stay tuned for more insights — and don’t underestimate the power of “forgotten automation.”