AS/RS in Malaysia's Humid Climate: Decades of Reliable Operation

Malaysia: common and unique challenges

Since 1994, Daifuku Malaysia has been advancing the factory and warehouse automation in the country

Malaysia’s logistics and manufacturing sectors are evolving rapidly. The growth of e-commerce, rising expectations for speed and accuracy, and the country’s role as a manufacturing hub especially in electronics, chemicals and semiconductors are driving demand for high throughput, reliable warehouse automation.

At the same time, Malaysia presents challenging operating conditions. High humidity and temperature swings accelerate corrosion, affect sensors, and shorten the lifespan of electronic components and batteries (*1-4). To answer these challenges, let’s explore the latest automation trends and what proven systems reveal about long-term performance.

New Technologies Facing Persistent Challenges

The automation landscape in Malaysia is changing fast. AMRs and four-way shuttle systems have recently gained attention, offering new concepts in warehouse design. However, these are still relatively new technologies, and their long-term resilience under Malaysia’s hot and humid climate is yet to be proven.

In a corrosive environment, electronic components such as circuits, sensors, and batteries face continuous stress. Lithium-ion batteries commonly used in mobile robots are particularly sensitive to heat and humidity, and their lifespan may shorten without controlled temperature and humidity levels. In an ambient warehouse with only ceiling fans, where humidity is not controlled and heat is managed solely by airflow, maintaining a long service life for newer technologies such as AMRs may require dedicated environmental control. This, in turn, increases both energy use and maintenance costs.

Despite these challenges, many Daifuku automated systems installed decades ago continue to operate without interruption. This enduring performance is not the result of special local adaptations, but Daifuku’s standard equipment, built in Japan to Japanese manufacturing standards, which is highly reputed in Malaysia. Decades of operation in Malaysia show that, with proper preventive maintenance, these systems can sustain performance consistently over time. This experience accumulated under such demanding conditions provides a clear benchmark for evaluating automation, not by how new the technology is, but by how consistently it performs.

Proven Systems That Endure

Standard AS/RS equipment continues to demonstrate its value through long-term durability. Many Daifuku installations in Malaysia have been operating for over 20 years, providing steady operational continuity despite demanding environments. Having entered the Malaysian market more than 30 years ago, Daifuku offers clear examples of this resilience:

• Major chemicals company: Multi-crane AS/RS in 1989, still running after multiple expansions.
• Leading paint manufacturer: First system in 1989, expanded in 1994, operating reliably today.
• Major semiconductor company: High-precision AS/RS commissioned in 2003, expanded in 2016.

These examples highlight how standard equipment without regional customization can withstand tropical conditions for decades while maintaining operational efficiency.

Lifecycle Engineering Matters

Daifuku Mini Load AS/RS installed in Malaysia

When choosing automation, total lifecycle cost is just as important as the initial purchase price. Factors such as energy consumption, spare parts replacement, software updates, and service response times determine whether a system lasts decades or requires early replacement.

Equipment built to global industrial standards with corrosion-resistant finishes, sealed electronics, and high-precision drives has proven capable of maintained performance under humid conditions year after year. Its cranes draw power continuously from a bus bar, eliminating the limitations of battery-based systems and ensuring stable operation. Combined with skilled local engineers who provide rapid diagnostics and maintenance, these systems maintain uptime even during peak operational periods.

Looking Ahead

Daifuku Sorting Transfer Vehicle (STV) installed in Malaysia

As Malaysia’s automation market continues to evolve, users are likely to combine fixed AS/RS, shuttle systems, AMRs, and integrated software to meet different operational goals. In environments where heat, humidity, and heavy daily workloads challenge equipment, durability, maintainability, and consistent throughput are the true measures of system quality.

The decades of proven performance of AS/RS installations in Malaysia show that well-engineered standard equipment can continue delivering reliable operation long after the initial ROI period. Newer mobile technologies may appear economical today, but their future service and component requirements tend to become more apparent over time. For warehouse operators, this track record offers a clear benchmark: the most reliable system is the one that performs consistently day after day, year after year.

Arif Shakri

Project & Service, Intralogistics, Daifuku Malaysia
Arif joined the Daifuku Group in 2021 and currently serves as a Project & Service Officer at Daifuku Malaysia. He plays a key role in overseeing project execution and delivering high-quality after-sales support. With a strong technical foundation and hands-on experience in automated material handling systems, Arif ensures that customer operations run smoothly, reliably, and efficiently.