--- title: "400+ bots, 14 levels, one private 5G network — and 90% less downtime" date: 2026-07-23T16:11:00+10:00 author: Pradhyum canonical_url: "https://celona.io/resources/automated-distribution-center-bots-private-5g" section: Resources --- / Case Study | Warehousing & logistics | Fully automated distribution center # 400+ bots, 14 levels, one private 5G network — and 90% less downtime Wi-Fi roaming kept dropping 400+ bots mid-aisle. Private 5G covers all 14 levels on 28 APs - 90% less downtime. ![Fullyautomated WH2](https://celona.io/volumes/images/FullyautomatedWH2.png) 400+ bots at 30 mph+ inside the cages 61K/day seamless handovers - no dropped bots 28 APs Wi-Fi vs private 5G (~10× fewer) 90% reduction in downtime / At a glance ## Bots that never drop the network. ### \_01 The Challenge - 400+ bots moving at 30 mph+ inside 7 ft × 300 ft multi-level cages - 600K sq-ft (~10 football fields), 14 levels to cover - Wi-Fi roaming failed — handoffs dropped bots and halted operations - Blanketing it with Wi-Fi took ~120 access points ### \_02 The Solution - Celona private 5G across all 600K sq-ft and 14 levels - Just 28 private 5G APs replace ~120 Wi-Fi APs - Seamless, network-controlled handover for fast-moving bots - Onboard cellular gateways on each bot ### \_03 The Outcome - Pervasive coverage across every level — no dead zones - ~61,000 handovers a day, all seamless — no dropped bots - 90% reduction in downtime from seamless mobility - Faster rollouts with up to 10× fewer APs to deploy A fully automated distribution center runs on bots - 400+ of them, moving at 30 mph and faster inside tall, caged aisles that climb 14 levels across roughly 600,000 square feet (about ten football fields). When the bots move, they pick and distribute; when they lose the network, they stop. Keeping every bot continuously connected, everywhere, at speed, is the whole game. ## Why Wi-Fi couldn't keep up The operation's Wi-Fi couldn't roam fast enough for bots traveling at 30 mph through steel-caged, multi-level racking. ![Fullyautomated WH](https://celona.io/volumes/images/Resources/_830x1024_fit_center-center_70_none_ffffff/56675/FullyautomatedWH.webp) Handoffs between access points dropped connections, and a disconnected bot halts - stalling picking and distribution. Covering the space with Wi-Fi also meant hundreds of APs to blanket the 600K sq-ft, 14-level structure, with all the cabling and tuning that implies - and it still left the roaming problem unsolved. ## One private 5G layer, 28 APs Celona deployed private 5G across the entire facility - all 600,000 sq ft and all 14 levels - with just 28 access points, ~10% Wi-Fi APs it would have taken. Private cellular's higher transmit power and link budget reach deep into the caged, multi-level racking, and its native, network-controlled handover keeps fast-moving bots connected as they cross cell boundaries at speed. Each bot connects through an onboard cellular gateway, so the fleet rides one deterministic network instead of contending with best-effort Wi-Fi. ## The outcome The result is pervasive coverage with no dead zones across every level, and the handoff and disconnect issues are gone. The network handles on the order of 61,000 handovers a day, all seamless, so bots keep moving. ![Picture1](https://celona.io/volumes/images/Resources/_768x332_fit_center-center_70_none_ffffff/56677/Picture1.webp) Predictable, always-connected mobility cut downtime by 90%. In a fully automated DC the stakes are high - bot downtime can run on the order of $50,000 a day (approximate industry estimate, not customer-reported) - so cutting it by 90% protects real throughput and revenue. And because of fewer APs, rollouts are far faster and simpler - up to a 10× reduction in the access points needed to cover the warehouse, with correspondingly less cabling and maintenance. At a Glance Customer**Fully automated distribution center** Vertical**Warehousing & logistics** Facility**600K sq-ft, 14 levels; 7 ft × 300 ft bot cages** Location**Confidential** Spectrum**CBRS / private 5G** Solution - Celona private 5G - full 600K sq-ft, 14-level coverage - 28 private 5G APs (≈10× fewer than Wi-Fi) - Seamless, network-controlled handover for 30 mph+ bots - Onboard cellular gateways on each bot - Celona Edge + Orchestrator - 90% downtime reduction; up to 10× fewer APs / Related resources ## Go deeper More resources on private wireless for the enterprise. [Research Papers NEW ### Warehouse Deployment: A Comparative Measurement Study of Commercial Wi-Fi and CBRS Systems, Published in 2023 International Conference on Computing, Networking and Communications (ICNC) Based on live warehouse trials, this paper compares Wi-Fi and CBRS under load and mobility, analyzing latency, packet loss, and throughput. It shows CBRS maintaining stable performance for mobile and delay-sensitive workloads where Wi-Fi degrades due to contention and roaming. Warehousing & logistics · Aug 2026 ](https://celona.io/resources/warehouse-deployment-a-comparative-measurement-study-of-commercial-wi-fi-and-cbrs-systems-published-in-2023-international-conference-on-computing-networking-and-communications-icnc) [Research Papers NEW ### A Measurement Campaign of Commercial Private Network Deployment in Indoor and Outdoor Environments, Published in 2024 IEEE 100th Vehicular Technology Conference (VTC) This multi-site study measures private LTE/5G performance across refineries, warehouses, parking lots, and distribution centers. It correlates theoretical models with field data to show consistent gains in latency, coverage, and mobility for mission-critical applications. Warehousing & logistics · Oil & gas · Aug 2026 ](https://celona.io/resources/a-measurement-campaign-of-commercial-private-network-deployment-in-indoor-and-outdoor-environments-published-in-2024-ieee-100th-vehicular-technology-conference-vtc) [Webinars NEW ### 10 Considerations for Robust Private 5G Wireless Implementation for Yard Management Watch this architect led webinar to discover how private 5G enhances yard operations with reliable, high-speed connectivity for real-time tracking, security, and worker communication. Warehousing & logistics · Aug 2026 ](https://celona.io/resources/10-considerations-for-robust-private-5g-wireless-implementation-for-yard-management) [Access all Resources ](https://celona.io/resources) / Next step ## See what Celona Orion can do for your plant Talk to the team behind Del Conca's deployment, or take the platform for a spin. [ Request a demo → ](https://celona.io/contact-us) [ Explore the platform → ](https://celona.io/manufacturing)