Warehouse planning tool - What does a high-bay warehouse cost?

Welcome to our warehouse planning tool. We present two alternative solutions for your desired warehouse size: An automated and a manually operated logistics system.
In addition to the floor space, you will receive a rough cost framework and the number of people you need to operate the logistics solution. We will also give you an indication of the possible throughput capacity of the assumed configuration.

Try it out! The evaluation is free and anonymous.

* Permissible input ranges:
Container: 5000 to 30000
Pallet: 2000 to 10000

The calculation is based on a number of assumptions. These are only plausible for a limited range of values. If your requirements lie outside this value range, you have the option of starting an individual query on the results page.

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Benjamin Fritsch

Consultant Logistics

T +49 2261 987-506
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Excursus: High-bay warehouse costs

A high-bay warehouse is a specialized form of storage system that enables efficient use of space by storing goods vertically on multiple levels. An automated high -bay warehouse can be up to 45 meters high. However, the cost of a high-bay warehouse can vary and depends on many factors.

The breakdown of costs can be very different for manual and automated high-bay warehouses.
An overview of the advantages and disadvantages of automated high-bay warehouses compared to manual solutions can be found here.
Here are some important points to consider in relation to the costs of a high-bay warehouse:

Investment costs for setting up and building the high-bay warehouse

  1. Land costs: Costs for the acquisition of the land on which the warehouse is to be built.
  2. Construction costs: Costs for materials, construction, architects, etc.
  3. Racking systems: Costs for the special high-bay racking and its assembly.
  4. Technology: Costs for automated systems, warehouse management software, barcode scanners, etc.
  5. Automated systems generate higher costs for technology and lower space costs.

High-bay warehouse costs for operation

  1. Personnel: Costs for warehouse employees, shift supervisors, maintenance personnel, etc.
  2. Energy costs: Electricity for lighting, heating, cooling and operation of machines.
  3. Maintenance and repair: Costs for the maintenance of racking systems, conveyor technology and other equipment.
  4. Insurance: Costs for building, liability and other insurances.
  5. Automated systems generate higher costs for maintenance and repair and save on personnel costs.

High-bay warehouse Costs for warehousing

  1. Inventory costs: Costs for the storage of goods, including wear and tear and spoilage.
  2. Current assets: Costs for tied-up capital in the form of stored goods.
  3. Consumables: Cartons, films, filling material, labels, containers / pallets, ...

Other costs for high-bay warehouses

  1. Financing costs: Interest on loans taken out to finance the construction or modernization.
  2. License and software updates: Costs for updating software and acquiring new licenses.

Unforeseen costs for high-bay warehouse

  1. Emergencies: Costs for unforeseen repairs or breakdowns.
  2. Market fluctuations: Changes in prices for energy, labor, etc.
  3. Each of these points can have a significant impact on the total cost of a high-bay warehouse and should therefore be carefully considered during planning and operation.

Worth knowing

Advantages and disadvantages of automated logistics systems

We have compiled further information on the question of whether or not automation is worthwhile in your warehouse on a separate page. There you will also find a study by Unitechnik on this topic as well as a white paper.

Click here to go to the page:

Advantages and disadvantages of automated logistics systems

Logistics Consulting


We believe that a good planning process needs a clear and transparent structure. That's why we have developed the three-phase plan to help you future-proof your logistics.

Find out here how we go about it:

To Logistics Consulting

FAQ: Costs for high-bay warehouses

The basic costs for the construction of a high-bay warehouse include the land, the construction of the building, the installation of the racking systems and any necessary technologies such as warehouse management systems and automation technology. Automated systems generate higher costs for technology and lower space costs.

Ongoing operating costs can include personnel, energy, maintenance and repairs, insurance and logistics. The costs for warehousing and inventory management must also be taken into account. Automated systems generate higher costs for maintenance and repairs and save on personnel costs.

The personnel and energy costs can vary greatly depending on the size of the warehouse, the location and the degree of automation. A manually operated warehouse usually has higher personnel costs than an automated warehouse. It is advisable to carry out detailed calculations based on the specific requirements.

Maintenance and servicing requires well-qualified personnel. The effort required depends on the size and complexity of the logistics system. The useful life of the systems also plays a role. Manually operated warehouses require less maintenance and servicing.

Automation can increase initial costs but reduce operating costs, as it is often more efficient and requires fewer staff. The costs of implementing and maintaining the automation technology should also be taken into account.

Insurance is an important item and can vary depending on the type of goods stored and the location of the warehouse. This includes building, liability and business interruption insurance.

There are several financing options, including bank loans, leasing options or government subsidies. The financing costs, such as interest on loans, should also be included in the total cost calculation.