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Locus Robotics has announced a technical collaboration with HelloFresh, involving a cold-storage hardware modification that has allowed the meal kit provider to expand its chilled fulfilment capacity from 100 SKUs to 500 SKUs. This increase supports expanded menu variety across the HelloFresh brand portfolio, including its brand Factor.

The project addresses the limitations of standard battery-powered autonomous mobile robots (AMRs) in refrigerated environments, where cold temperatures can impact battery efficiency and long-term hardware reliability.

Cold Storage Technical Adaptations

Operating within refrigerated conditions requires equipment capable of sustained performance. To meet the specific requirements of HelloFresh, Locus Robotics developed a heated motor enhancement and modified charging systems for its Locus Origin robots. These adjustments allow the robots to remain within the chilled environment for both work tasks and charging, ensuring continuous operational uptime.

The implementation follows an initial pilot phase conducted in July 2025, which utilised 13 Locus Origin robots. Following the successful testing of the modified hardware, HelloFresh scaled the deployment with an additional 26 units, with further plans to integrate the technology into EveryPlate fulfilment operations later this year.

Operational Efficiency and Fulfilment Speed

The integration of the automated system has impacted mission speed within the facility. According to operational data from the deployment, the Locus Origin robots averaged a mission time of three minutes and 36 seconds from order induction to box drop-off.

This automation model provides an alternative to traditional fixed conveyor systems. By utilising a flexible AMR platform, the facility avoids the risk of single-point failures associated with conveyor belt systems, allowing for a more agile response to fluctuating order volumes.

The current deployment supports approximately 12,000 square feet of chilled fulfilment space, facilitating two high-speed meal kit picking lines. The system is designed to integrate with existing operational layouts, providing a scalable path for meal kit providers to manage high-volume and high-variety inventory in temperature-controlled settings.