GreyOrange has launched a new warehouse simulation platform designed to help operators model automation deployments, estimate costs, and predict system performance before implementing changes on-site.
Called GreyMatter Foundry, the platform combines warehouse flow design, layout planning, and automation sizing within a single simulation environment. The company says the system can model mixed fleets of robots, automation equipment, and human workers operating together across complex fulfillment environments.
The launch reflects growing interest in AI-driven warehouse orchestration systems capable of managing increasingly heterogeneous automation environments, where facilities often combine technologies from multiple vendors alongside manual workflows.
GreyOrange says the new platform draws on operational data gathered through its GreyMatter orchestration software, which the company describes as being deployed across thousands of warehouses worldwide. According to GreyOrange, the system currently orchestrates more than 130,000 robotic agents through its Certified Ranger Network.
The company says GreyMatter Foundry allows warehouse operators, systems integrators, and fulfillment teams to simulate different automation scenarios and evaluate how changes in layout, labor availability, storage requirements, or robotic systems could affect throughput and operational efficiency.
Among the platform’s capabilities are the ability to model multiple robotic systems simultaneously, simulate labor shortages or peak-season demand, and test warehouse layouts against future growth scenarios over five- and 10-year planning horizons.
GreyOrange says the system can also generate 3D warehouse visualizations and ROI calculations while running multiple simulations in parallel to compare different operational approaches.
The platform includes what GreyOrange calls an AI-powered “design copilot”, allowing users to guide simulations through conversational prompts or predefined templates.
“Warehouse automation should not be a leap of faith,” said Saurabh Gupta, CTO for GreyOrange. “By putting the intelligence of our live, global GreyMatter network behind every simulation, we give distributors, 3PL’s, retailers and integrators a crystal ball grounded in real-world data.
“Whether you’re designing from a greenfield scenario or rethinking an existing operation, Foundry lets you test thousands of scenarios, stress-test for peak demand, and arrive at deployment day with confidence.”
GreyOrange says the platform is designed to support both new warehouse projects and upgrades to existing operations, particularly as operators face increasing pressure to manage labor shortages, rising throughput demands, and more complex fulfillment requirements.
The company says simulations can be completed in hours rather than weeks, allowing operators to evaluate multiple automation strategies before committing capital investment.
