How Advanced Scanning Technologies Are Shaping the Future

Overcoming the Pitfalls of Inaccurate Information

In the fast-moving world of materials handling, the smallest error can cascade into significant setbacks. Inaccurate or out-of-date facility drawings-long a frustrating reality-introduce hidden costs, lost time, and quality control issues. As the industry pushes toward ever-higher levels of automation and efficiency, these old problems demand cutting-edge solutions.

Enter Light Detection and Ranging (LiDAR): More Than a 3D Scan

Light Detection and Ranging (LiDAR) technology is transforming the way material handling systems are designed, installed, and maintained. Tools like the Leica BLK360 scanner generate detailed, data-rich 3D point clouds and high-definition images, capturing everything from building geometry to the precise placement of existing assets. This leap ensures that conveyors, robots, sorters, and storage systems are not just “close enough,” but exactly where they need to be-eliminating costly surprises.

“We’ve used the scanner on a number of projects, and it has saved us a lot of time in field surveys, and has helped us avoid some serious field modifications due to inaccurate customer building drawings,” explains David Almquist, a senior design engineer at FloStor.

Real-World Impact: From Headaches to High Performance

Consider the case of a plastics closure manufacturer: traditional drawings placed a structural column in one location, but a LiDAR scan revealed it was actually 20 inches away from where the plans indicated. By catching this before installation, FloStor’s team avoided what could have been a costly, time-consuming disaster-demonstrating in practice how advanced scanning is not just a safety net, but a springboard to smarter workflows.

For the world’s largest online retailer, the challenge was integrating new sorting technology into a complex web of existing conveyors. Using 3D visualization, FloStor provided clear, immersive images showing exactly how new and old systems would interact. The result? Peace of mind, better vendor collaboration, and even discussions about making advanced scanning a standard requirement for all partners.

In another project, even the absence of proper documentation was no barrier. When a parcel service company only had access to an outdated real estate flyer as their building “plan,” FloStor’s team scanned the facility and created a precise, actionable AutoCAD layout-setting the stage for error-free automation.

What’s Next? The Broader Implications of Smarter Scanning

The power of technologies like LiDAR doesn’t end with installation. Imagine a near future where:

• Continuous scanning enables real-time facility optimization, feeding data to AI systems that predict and prevent bottlenecks.
• Digital twins-virtual, living models of your operation-are updated automatically with every change, enabling remote troubleshooting and rapid reconfiguration.
• Integration with wearable tech allows human workers to collaborate seamlessly with robots, guided by the same live spatial data.
• Sustainability practices benefit directly, as accurate spatial intelligence reduces material waste, prevents costly retrofits, and helps optimize energy consumption.
• Scans and data analytics inform not just layout planning, but also equipment maintenance, worker safety, and even insurance risk assessments.

Looking Forward: Questions Driving the Next Wave of Innovation

As advanced scanning becomes standard, the industry must ask:

• How can we harness ML and AI to make scan data smarter, not just more detailed?
• What new business models and customer expectations emerge when spatial accuracy is guaranteed?
• How will workforce roles and training evolve when technology takes over routine measurement and layout tasks?
• What global standards and best practices are needed as these technologies spread across different regions and regulatory environments?

What if the routine headaches of inaccurate layouts, last-minute field changes, and wasted resources became relics of the past? Advanced scanning technologies like LiDAR are leading us there-opening up opportunities for efficiency, safety, sustainability, and competitive advantage that are just beginning to be realized.

The future of materials handling isn’t just about moving goods. It’s about moving smarter, faster, and with absolute confidence-every step of the way.