Simon Allen, MD, Breathe Technologies
In an industry where speed, precision, and cost-efficiency rule, warehouse operations – particularly the picking process – remain a surprising pain point.
Often accounting for up to 40% of total warehouse costs, traditional picking processes rely heavily on manual labour, inefficient workflows and inflexible systems.
But a quiet revolution is underway, and at the heart of it are products that improve productivity, reduce waste, and elevate performance on the warehouse floor while advancing sustainability through reduced packaging waste and optimised trailer fill
Manual picking in warehouses is one of the most labour-intensive and inefficient processes in logistics. Workers walk miles every day retrieving items, often following sub-optimal routes. Even in facilities equipped with automation, inefficiencies persist due to a lack of smart orchestration.
That’s where Breathe Technologies’ Orquestr8 Pick makes its mark – a solution that’s using Artificial Intelligence (AI) and Machine Learning (ML) to dramatically improve the picking process.
Designed specifically for manual and hybrid warehouse environments, the solution brings AI -powered intelligence to picking operations, and unlike traditional systems, Orquestr8 Pick uses ML to continuously learn from completed tasks, optimising future operations in real time.
The impact is immediate and measurable. Customers using Orquestr8 Pick report:
- 65% reduction in walking distance
- 30–35% increase in picking productivity
- 5% drop in shipping containers and boxes used
- 5% reduction in shipping volume per week
- Annual savings of 5% truck journeys and CO? emissions
These aren’t just metrics; they represent real-world efficiencies that are transforming how warehouses operate – both for retail distribution centers and e-commerce fulfillment hubs.
A digital twin mirrors the physical layout and picking operation for each customer, allowing for testing and analysis in the virtual world first. For example, simulation of customer data from a grocery distribution centre using Orquestr8 Pick showed a 24,877 km saving in walking distance per month- enough to circle the globe over seven times in a single year. Elsewhere, a major high street retailer has seen enough benefit to consider deploying the solution across its international network of warehouses.
One of the most compelling features of Orquestr8 Pick is its accessibility. Unlike large-scale automation solutions that require capital-heavy upfront investment, Orquestr8 Pick is available via monthly subscription, with no upfront costs. It integrates seamlessly with existing Warehouse Management Systems (WMS) and can be deployed within 12 weeks, supported by a comprehensive three-tier support structure, including a 24/7 help desk and tailored service agreements.
This ease of deployment means organisations can see faster ROI, adapt more quickly to changing market demands, and scale their operations with confidence.
The intuitive user interface and rich reporting tools empower managers to make smarter decisions. From optimising walking routes to identifying bottlenecks, Orquestr8 Pick provides transparency and actionable insights throughout the operation.
By optimising container fill and reducing the number of boxes used, Orquestr8 Pick doesn’t just improve operational metrics – it also supports broader sustainability goals. One customer alone has saved 5% containers per week, avoiding the carbon footprint of 5% truck journeys annually.
The solution is also creating jobs: four new roles have already been added within Breathe Technologies due to demand and adoption, with more expected as the solution scales.
The system was developed thanks to support from the networks available at our home at Sci-Tech Daresbury, and benefited from a Knowledge Transfer Partnership (KTP) with Manchester Metropolitan University, funded by Innovate UK.
Products such as Orquestr8 Pick are not only changing how warehouses operate – they’re redefining what’s possible when AI and ML is applied pragmatically, transparently, and with real business outcomes in mind.
For further information, please contact:
Nicola Halliday at Breathe Technologies – nicola.h@breathetech.co.uk
Visit us at Breathetech.co.uk or follow us on LinkedIn
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