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How Danfoss boosted output and safety without expanding

Case Study

7/7/2025

Factory floor with autonomous warehouse robots in operation

Industry

Logistics

Application

Transport

Robot Solution

LD-90

Solving space and manual handling challenges in warehouse operations

Danfoss Power Solutions, a global leader in mobile hydraulics, faced a critical challenge at its Nordborg facility: rapid growth had led to a shortage of factory floor space, while traditional warehouse operations—relying on manual handling of heavy boxes—put physical strain on workers, increased safety risks, and limited operational flexibility. Expanding the building wasn’t feasible, so Danfoss sought a smarter, more creative solution to improve both space efficiency and workplace ergonomics.

To overcome these challenges, Danfoss collaborated with OMRON, RoboTool, and Nord Modules to deploy a cutting-edge robotic system. Together, they implemented LD-90 Autonomous Mobile Robots (AMRs), an AutoStore automated storage solution, and an industrial robot for seamless logistics. RoboTool, as one of OMRON’s integration partners, played a pivotal role in bringing the system to life, while Nord Modules developed the mobile robot solution.

With this new setup, manual lifting was eliminated. OMRON’s mobile robots transport components between the AutoStore system and the factory floor, while an industrial robot handles loading and unloading—creating a fully automated logistics flow with no human contact.

The impact was immediate and far-reaching. Danfoss now benefits from a safer working environment, improved ergonomics, and optimized use of space—860 square meters serve production more efficiently than ever. The system’s flexibility allows Danfoss to scale production up or down as demand changes, providing a robust model for future growth.

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“The challenge was that we experienced significant growth over the past year, which resulted in a lack of physical space on our factory floor. Expanding the building wasn’t an option, so we had to come up with a smarter and more creative solution.” — Martin Ole Madsen, Manager Operations Excellence, Danfoss Power Solutions

Results at a glance:

Zero manual handling, improving workplace safety and ergonomics
Enhanced space efficiency with compact, automated storage and transport
Scalable production capacity to match order volumes
High level of automation integrating mobile, industrial, and warehouse robots
Successful collaboration with RoboTool and Nord Modules
Industry recognition with a nomination for the DIRA Automation Award 2024

Forward-thinking automation for manufacturing

Danfoss Power Solutions’ adoption of autonomous warehouse robots demonstrates how creative collaboration, and advanced automation can address real-world manufacturing challenges. The project not only solved immediate space and safety issues but also set a benchmark for innovation in the industry. Curious how Autonomous Mobile Robots could solve space or handling challenges in your own facility? Let’s chat and share ideas.