Digital Decanting: Robotics in container unloading

The logistics sector globally is entering a new phase of automation, with robotics increasingly deployed to tackle one of the most labour-intensive and time-sensitive tasks: unloading containers. This shift is not just about technology adoption but a strategic response to structural challenges in global supply chains, including labour shortages, rising costs, and the need for resilience.

Why Robotics in Container Unloading Matters

Container unloading has traditionally relied on manual labour following a “handball” process, creating bottlenecks in ports, warehouses, and distribution centres. The process is physically demanding, slow, and prone to errors, particularly in sectors such as retail and food manufacturing where speed and accuracy are critical. Robotics offers a solution that combines precision, consistency, and scalability. Container fill has also been area of optimisation for many supply chain leaders ensuring maximum cost efficiency per movement often at a further detriment to unloading capability.

The business case for robotic deployment is increasingly appealing:

• Rising labour cost mitigation: Automation reduces dependency on seasonal or temporary labour.

• Throughput gains: Robotics can operate continuously, improving container turnaround times.

• Safety improvements: Minimising human exposure to hazardous environments lowers injury risk and insurance costs.

Boston Dynamics introduced Stretch in 2023

Designed specifically for unloading boxes from containers and trucks. It uses computer vision and suction-based grippers to handle diverse package types, making it attractive for e-commerce and retail distribution. DHL Supply Chain have shared their integration of Stretch robots into their North American, UK and soon to be European distribution centres. These robots have a pick-rate of 700 cases per hour with interchangeable grippers allowing the robot to handle a diverse range of products.

Key Features and Capabilities

• Vision-driven precision: Equipped with advanced computer vision, Stretch identifies and handles mixed SKUs in the same container without requiring pre-sorted loads. This is critical for e-commerce and retail operations where variability is high.

• High throughput: Designed to operate continuously, Stretch can unload up to 700 cases per hour, significantly reducing container dwell time and improving dock utilisation.

• Mobility and flexibility: Unlike fixed automation, Stretch is mobile and can be deployed across multiple dock doors, making it ideal for facilities with fluctuating inbound volumes.

• Safety and ergonomics: By removing humans from repetitive heavy lifting, Stretch reduces injury risk and supports compliance with health and safety standards.

Industry use cases

• Retail and e-commerce: High SKU variability and demand spikes make robotics essential for maintaining service levels.

• Food manufacturing: Robotics supports compliance with hygiene standards and accelerates inbound raw material handling. Robotics have an added benefit of being able to operate in coldchain and frozen environments continuously without colleague discomfort.

• Third-party logistics (3PL): Providers are investing heavily to differentiate on speed and reliability, particularly in temperature-controlled environments.

What do supply chain leaders need to consider?

The adoption of robotics in container unloading is a strategic enabler. Key implications include:

• Capital investment: Robotics requires upfront investment but delivers long-term savings through reduced labour costs and improved efficiency. Leaders must weigh ROI against alternative automation priorities and labour cost savings.

• Workforce transformation: Automation shifts labour needs and skillset from manual handling to technical oversight and maintenance. Upskilling programmes will be critical to avoid operational gaps.

• Network design: Faster unloading changes the economics of distribution hubs. Expect greater emphasis on automation-ready facilities.

• Resilience and sustainability: Robotics reduces reliance on volatile labour markets and supports sustainability goals by optimising energy use and reducing waste through precise handling.

Actions for supply chain leaders

Assess automation readiness: Audit current inbound processes to identify high-impact areas for robotics deployment. Asses both peak and off-peak periods separately to model an all-year-round outcome.

1. Engage with technology partners: Early collaboration with prospective providers can ensure a customer-focussed implementation and customisation. Gaining input from operational teams is key to reducing onboarding friction.

2. Plan for workforce transition: Develop training pathways for technical roles to ensure smooth integration.

3. Model ROI beyond labour savings: Include throughput gains, safety improvements, and sustainability benefits in investment cases.

In summary, robotics in container unloading is moving from pilot projects to mainstream adoption. For retail and food supply chains, the opportunity lies in leveraging this technology to unlock speed, resilience, and cost efficiency. Leaders who act now will set the pace for the next generation of automated logistics.

To read more about the latest technological innovations transforming supply chains, please visit our supply chain hub. On the hub, you can find our Supply Chain Trends 2026 report which uncovers the latest technological, sustainable and social advancements which we can expect to see emerge over the next 4 years. The highlights report provides a summary and is freely available for non-subscribers.