Case Study: Asian Paints achieves rapid high-throughput automated distribution and scalable, labor-free growth with Bastian Solutions

Asian Paints - Customer Case Study

Asian Paints engaged Bastian Solutions to automate distribution from its new 130‑acre Rohtak facility and support a four‑phase expansion toward a final production capacity of about 400,000 kl/yr. The challenge was to build a packaged materials and finished‑goods ASRS with conveyors, lifts and a WCS that could handle an anticipated 264 pallets per hour and enable direct distribution to dealers while scaling capacity over the next 4–5 years.

Bastian Solutions delivered an integrated solution including pallet conveyors, barcode scanning, an Exacta warehouse control system with SAP WMS interface, 32 ASRS cranes and supporting equipment (depalletizers, lifts and transfer cars) to fully automate pallet flows. Bastian Solutions brought Phase 1 to full production within 3–4 months of handover, met the 264 pallets/hr requirement, positioned Asian Paints to grow order volume through Phases 2–4 without adding labor, and achieved dramatic improvements in stock accuracy, productivity and throughput.

Asian Paints