Decathlon increases warehouse productivity twofold by implementing Exotec robots at seven locations throughout Europe | TNW

      The largest sporting goods retailer in the world has automated seven of its European warehouses with robots, and preliminary data indicate that these machines are proving effective. Decathlon announced on Tuesday that its collaboration with Exotec, a French company specializing in warehouse robotics, has resulted in what it describes as substantial productivity improvements at facilities in France, the United Kingdom, Portugal, Italy, and Germany.

      The statistics are compelling. At its warehouse in Setúbal, Portugal, Decathlon reported that the site now processes 114,000 orders daily, which is double the 57,000 it handled prior to automation. A warehouse in France nearly doubled its capacity to replenish stores, increasing from 37 to 73. Meanwhile, at the Northampton location in England, workers who used to walk over 10 kilometers daily now cover less than one kilometer. Additionally, incidents related to order picking at this site have decreased significantly, falling from one in every 5,000 to one in 10,000.

      These are not the humanoid robots typically seen in the news. Exotec’s leading product, known as Skypod, consists of a fleet of wheeled machines about the size and shape of a large Roomba. Each machine carries storage bins and can ascend proprietary shelving systems to heights of approximately 14 meters, efficiently retrieving and delivering hundreds of thousands of items each day. Typically, a Decathlon site operates with between 150 and 200 Skypods, alongside automatic depalletisers, carton-opening machines, RFID tunnels, and palletisers. The entire system is managed by Deepsky, Exotec’s warehouse execution software.

      The argument for reduced footprint

      Romain Moulin, cofounder and CEO of Exotec, explained that the primary benefit is not merely speed but also density. In traditional warehouses, shelves are stacked to about two meters high to accommodate human workers, forcing companies to expand their facilities as order volumes increase. Moulin noted that the average warehouse size is around 18,000 square meters. With the vertical capabilities of Skypods, Exotec claims it can shrink that footprint to approximately 6,000 square meters without losing capacity, since the same volume of goods occupies significantly less floor space.

      This situation implies that retailers can either function in smaller, less expensive buildings or use the extra space for other operations. For Decathlon, which operates over 1,800 stores and employs 101,000 people globally, the attraction is clear: a standardized warehouse model that can be quickly implemented across various markets. Moulin stated that Exotec can establish a new automated warehouse every four months.

      Impacts on workers

      A common concern with warehouse automation is the fate of the workers who previously performed picking tasks. Exotec’s own data provides a partial answer. At one location, the number of designated pickers dropped from 50 to 12 after Skypods were introduced, with the remaining staff reassigned to roles like processing returns and repairs.

      Moulin framed this change as an enhancement of working conditions rather than a reduction in workforce. As a result, pickers no longer have to walk 10 kilometers per shift, the injury rate has declined, and the increased throughput means there are still opportunities for reassigned workers to manage the higher volume of goods.

      While this perspective is convenient, it also reveals a real structural problem. There are significant and worsening labor shortages in warehouse logistics across Europe, Japan, and the United States. Moulin stated that every client he talks to, regardless of location, reports challenges in recruiting pickers. The warehouse robotics market, projected to be worth around $8.75 billion by 2026, is growing at over 18 percent annually, largely fueled by this shortage.

      Avoiding humanoids

      The article’s most striking detail may be Exotec's decision to avoid developing humanoid robots. While companies like BMW and Amazon experiment with bipedal humanoid robots for factory and warehouse operations, Moulin dismissed this approach for his purpose, arguing that having a humanoid push a cart for 10 kilometers a day simply replicates the problem automation aims to resolve. Instead, Exotec employs specially designed machines optimized for specific tasks, enhanced with AI for routing, scheduling, and inventory management.

      This reflects a distinctly European philosophy towards industrial robotics: practical, specialized, and uninterested in showmanship. Founded in 2015, Exotec achieved unicorn status in 2022 after raising $335 million at a valuation of $2 billion, backed by Goldman Sachs. Its annual revenue has since reached approximately €300 million, with the Skypod system operating at over 200 customer locations globally, including Uniqlo, Carrefour, Gap, and Geodis.

      The Decathlon rollout, referred to as the Skyfleet program, is its most ambitious multi-site deployment to date. Whether it sets a precedent for how European retailers manage their supply chains will depend on whether the productivity improvements hold as the system expands. For the 38 former pickers at that one site who have transitioned to other