DHL Supply Chain Brings One-Touch-Picking to Czech Republic With Fully Automated Packaging Line at Czech’s Largest Distribution Center in Jirny
Press Release: Prague, 09 December 2025
- DHL Supply Chain launches a fully automated packaging line – delivering more efficient packing, reduced material use, and minimized air volume for improved transport utilization and sustainability.
- The new system is supported by collaborative assisted picking robots, including scalable Chuck AMRs from Ocado Intelligent Automation.
- Automation eases repetitive tasks, creates more engaging, value-added work, and contributes to sustainable operations through optimized packaging and transport efficiency.
DHL Supply Chain continues its automation and digitalization journey at its largest distribution center in Jirny, Czech Republic. The latest milestone is the introduction of a fully automated packaging line that significantly improves order processing efficiency, optimizes packaging, and enhances working conditions for employees. Building on successful deployments in other regions such as Europe and the UK, DHL showcases its ability to scale proven technology seamlessly across borders. At the heart of this approach is the concept of one-touch-picking, delivering maximum efficiency and consistency throughout the entire picking process.
„The new line consists of four machines - two for erecting boxes and two for closing, inspecting, and labeling them - connected by a conveyor system and supported by assisted picking robots, the so-called Chuck robots from 6Rivers. Currently, 24 of these Chuck robots operate daily, with the ability to scale up with additional 40 more robots during seasonal peaks - effectively tripling robotic capacity.
At the same time, the packaging line can fold and seal up to 960 boxes per hour, equivalent to the output of up to 35 workers in normal operation. To calculate the optimal package size, the system uses a cubistic algorithm, which significantly reduces packing and filling material as well as volumetric weight. This means fewer resources, less waste, and better truck utilization.” said Vladimír Kvítek, Business Unit Director DHL Supply Chain.
Technology that automatically adjusts box height to its contents eliminates the need for filler material and reduces parcel volume by up to 10%. As a result, more parcels fit into each truck, improving transport efficiency. All packaging materials are recyclable, and boxes are sealed with paper tape using water-based adhesive. An AI-powered system with cameras ensures correct packaging and accurate labeling.
The goal of this automation is clear: deliver direct efficiency improvements for customers while creating better working conditions for employees. By reducing physically demanding and repetitive tasks, we make work more ergonomic and engaging, strengthening employee retention and safety. Teams can now focus on operating the line and on tasks that create greater added value.
The modular design allows capacity to be increased by up to 50% if needed. Together with assisted picking robots and Robotic Process Automation (RPA) for administrative tasks, DHL Supply Chain has established a scalable automation ecosystem designed for future growth. RPA automates repetitive digital processes such as data entry or order updates, enabling employees to concentrate on higher-value activities.
The individual operations at the distribution center have been undergoing gradual modernization since 2019. After introducing a modern WMS system, robotic palletizing units, and assisted picking robots, the new packaging line marks another major step forward.