Solutions for automated warehouses and AutoStore™ systems
Forex and Lexan panels for logistics automation
Warehouse automation is today one of the cornerstones of Logistics 5.0.
Advanced systems such as AutoStore™ have revolutionized the way goods are stored and handled, introducing modular and robotic structures that operate continuously, precisely and safely. In order for these criteria to be fully met, every structural component of an AutoStore solution must ensure reliability, strength and light weight – requirements that find an ideal answer in engineering plastic materials.
Elastotecnica is the technical partner for the production of Forex and Lexan panels designed for automated warehouses and AutoStore™ systems. Our solutions are used for the enclosure and protective walls of automated logistics structures, offering safety, reliability and a high level of aesthetic customization.
Thanks to the extensive experience gained in custom plastic machining, we support installers and system integrators in the design and production of high-performance components, guaranteeing fast response times and consistent quality even for large-scale supplies.
Expanded PVC and polycarbonate panels for AutoStore™ systems
In automated warehouses, the structure that houses robots and storage modules requires components that are lightweight, durable and easy to customize.
Lexan panels (solid polycarbonate sheets, known for their high impact resistance and unbreakability, much lighter than glass and with excellent optical properties) and Forex panels (rigid expanded PVC sheets characterized by a closed-cell, homogeneous structure that makes them lightweight, rigid and easy to machine) are the most widely adopted solution for the protection and enclosure of AutoStore™ systems, as they offer an ideal balance between strength, transparency and design flexibility.
In AutoStore™ systems, panels are installed vertically along the load-bearing structure, creating continuous surfaces that integrate seamlessly with the grid modules. In addition to their protective barrier function, they define operational areas and allow the combination of opaque and transparent zones according to specific needs:
- Forex panels, available in white or colored versions, provide high mechanical resistance and a uniform appearance, ideal for creating clean, orderly surfaces that can be easily customized with graphics or company logos.
- Lexan panels ensure internal visibility of the structure and are essential in maintenance areas or where visual inspection of robots and storage bins is required.
Both sheet types can be combined within a single modular system, creating a true “technical mosaic” that merges design and functionality.
AutoStore™ protection panels by Elastotecnica are manufactured according to customer drawings, with customized cuts and drilling. They ensure fast and precise installation even on large dimensions, while maintaining tight tolerances and high-quality finishes.
The know-how developed in machining expanded PVC Forex and Lexan polycarbonate panels allows us to respond precisely to the needs of system integrators and installers operating in the automated logistics sector.
The benefits of Elastotecnica panels for automated vertical warehouses
In an automated warehouse, every structural element contributes to the overall efficiency of the system. For this reason, the choice of protective and cladding panels is a technical and functional aspect that directly affects performance, safety and maintenance.
Elastotecnica panels offer an excellent combination of precision, strength and light weight, facilitating installation and extending the service life of the enclosure over time. The dimensional accuracy of the cuts ensures optimal coupling between modules, reducing tolerances and micro-gaps; the mechanical strength of the materials, combined with their low weight, allows the creation of stable yet easily manageable structures, while the smooth, non-porous surface simplifies cleaning and routine maintenance.
Sheets can be customized in shape, color and finish to meet aesthetic or visual identification requirements. Opaque Forex versions are available in multiple color options, while Lexan panels allow the creation of transparent sections for visual inspection or robot supervision.
The entire Elastotecnica production process – from receipt of the technical drawing to delivery of the finished panels – is managed internally and fully traceable, ensuring consistent quality and compliance with project timelines. In addition, our flexible and dynamic structure guarantees fast production and supply times, even for large-scale orders.
Applications and materials
In the design of AutoStore™ systems, Lexan and Forex panels are complementary solutions that ensure high performance, long service life and maximum operational safety in automated warehouses.
Expanded PVC (Forex)
Expanded PVC, commercially known as Forex, is a lightweight yet extremely rigid plastic material, ideal for cladding and protective panels in automated warehouses. Its compact, impermeable surface resists moisture, chemical agents and temperature fluctuations, making it perfectly suited for intensive logistics environments. Available in white or colored versions, Forex allows aesthetic customization of the structure by integrating corporate colors, graphic patterns or color codes for internal signage.
Thanks to custom machining, Elastotecnica produces expanded PVC panels in any format, with customized cuts, holes and shapes to ensure simple, precise and long-lasting installation in automated vertical warehouses.
Transparent polycarbonate (Lexan)
Lexan is a solid, transparent polycarbonate that combines high impact resistance with excellent visibility. In automated warehouses and AutoStore™ systems, Lexan panels are used for covers and control walls where external monitoring of robot activity or picking operations is required.
Although lighter than glass, this material offers significantly higher mechanical resistance, which is essential in environments where impacts or vibrations may occur. Lexan polycarbonate is also resistant to UV radiation and aging: long-term transparency and ease of cleaning significantly reduce maintenance costs.
Customized variants and modular combinations
Depending on the project, Forex and Lexan panels can be combined in mixed configurations, with opaque surfaces for structural areas and transparent modules for inspection or visual control zones. This versatility makes it possible to create custom technical enclosures that are fully integrated into the automated warehouse structure and always compliant with customer or system integrator specifications.
Technical benefits for automated logistics
The use of engineering plastic panels in automated warehouses ensures:
- Reduced overall structure weight compared to metal solutions.
- Thermal and acoustic insulation, useful in indoor production or logistics environments.
- Ease of cleaning and hygiene, thanks to smooth, non-porous surfaces.
- Simplified maintenance, with panels that are easy to replace or integrate.
- Resistance to impacts and vibrations, ensuring long service life even in continuous 24/7 operation.
Thanks to these characteristics, expanded PVC Forex and Lexan polycarbonate panels are the ideal solution for AutoStore™ structures and automated warehouses across all sectors: industrial manufacturing, e-commerce and logistics, pharmaceutical and healthcare, food and beverage, retail and large-scale distribution, furniture, optics and small parts, and 3PL (third-party logistics).
Elastotecnica: the technical partner for logistics automation
Thanks to its in-depth know-how in custom plastic machining, Elastotecnica supports every phase of the project, from technical consulting to the production of finished panels. A flexible structure, precision machinery and fully controlled internal processes allow us to respond quickly and effectively to the needs of system integrators and installers in the logistics sector, supplying high-quality solutions for automated warehouses and AutoStore™ systems.
Our approach, focused on collaboration, customization and reliability, makes Elastotecnica a solid and responsive partner for those who design and build the logistics infrastructures of the future.
FAQ – Frequently Asked Questions About Automated Warehouses
What are automated warehouses and how do AutoStore™ systems work?
Automated warehouses are logistics systems that use robots, modular racking and control software to automatically manage storage, picking and material handling operations. AutoStore™ systems, in particular, are based on a grid structure in which small robots move along dedicated rails to retrieve and deposit bins. This innovative technology optimizes space and minimizes human intervention, increasing productivity, safety and operational accuracy.
Which materials are used for automated warehouse panels?
The most commonly used materials for automated vertical warehouses are expanded PVC (Forex) and solid polycarbonate (Lexan), chosen for their light weight, strength and dimensional stability. Forex, available in white or colored versions, is ideal for opaque panels and structural walls, while Lexan provides internal visibility thanks to its transparency and is often used in maintenance or control areas. Both materials ensure durability, ease of cleaning and extensive customization options.
What are the advantages of Forex and Lexan panels in automated warehouses?
In automated vertical warehouses, industrial plastic panels made of Lexan and Forex offer numerous advantages over traditional materials such as steel or glass:
- reduced weight and easier installation.
- resistance to impacts and vibrations generated by moving robots.
- smooth and non-porous surfaces that are easy to sanitize
- thermal and acoustic insulation, aesthetic and functional
- customization according to project needs
- higher safety compared to alternative materials
- long service life combined with exceptional ease of cleaning and maintenance.
For these reasons, expanded PVC Forex and Lexan polycarbonate are now considered the benchmark materials for AutoStore™ protection panels.
Is it possible to request custom-made panels based on technical drawings?
Yes. Elastotecnica manufactures PVC and polycarbonate panels according to drawings, adapting to the dimensional and functional specifications of each project. Panels can be cut, drilled, shaped and customized according to customer requirements and delivered ready for installation. This custom approach allows perfect integration of the panels into the AutoStore™ structure and optimizes installation, replacement and maintenance times.
Do you also provide technical consulting for international projects?
Absolutely. The experience gained by Elastotecnica in the production of industrial plastic panels allows us to collaborate with system integrators and installers on an international scale, supporting them in selecting the most suitable material and in optimizing supply planning. Our technical team ensures fast response times, full traceability and high quality standards, in line with the requirements of large-scale logistics automation projects.