How much does a Pick-to-Light system cost? Prices, cost drivers, and a calculation example

If you search for Pick-to-Light pricing, you’ll mostly find one thing: "Contact us for a quote." However, the question can be answered much more specifically. In this article, we break down the cost components of a Pick-to-Light system, the factors that truly drive the price, what a sample investment calculation for a picking zone looks like, and when the system pays for itself.

The short answer: Depending on the display type, hardware costs typically range between 10 and 250 euros per storage bin. However, the biggest price difference isn't in the modules themselves, but in the installation: wired systems require electrical work at every single bin. Wireless systems eliminate this entire step, which can lead to a comparatively quick return on investment. In our calculation example, this comes to around 15 to 16 months when taking the total system costs into account.

The five cost blocks of a Pick-to-Light system

1. Hardware per compartment. The module at the storage compartment is the most visible item: from a simple LED display with a confirmation button to an ePaper display. Market prices range between 10 and 250 euros per compartment, depending on the features. The rule of thumb: the more information that needs to be displayed directly at the compartment (quantity, item, order), the higher the module price.
2. Infrastructure and installation. This is where the market divides. Wired systems require power supply and data lines at every compartment: cable ducts, distributors, controllers, and an electrician. Depending on the shelving situation, this can quickly add up to 50 to 150 euros per compartment, plus downtime during installation. Wireless systems replace this with a few radio gateways (benchmark: approx. 1 gateway per 1000 sqm): the modules are mounted on the existing shelving and are ready for operation.
3. Software and license. Traditionally as a one-time license with a maintenance contract, or modernly as a SaaS subscription including updates, support, and hosting. The SaaS model shifts costs from investment to operation and is important for comparing offers: it is always advisable to compare the total costs over three to five years side by side.
4. Integration. The system must receive orders from ERP, WMS, or MES and report back confirmations. Whether this becomes a dedicated IT project or a configuration task is one of the biggest hidden price factors: custom-programmed interfaces can quickly cost a five-figure sum. Platforms with open standard interfaces (REST API, webhooks) reduce this to configuration and are ready for use in just a few hours.
5. Introduction and operation. Process analysis, pilot setup, training, and during operation, batteries or energy, occasional module replacement, and adjustments for product range changes. The last point in particular is underestimated: with wired systems, every layout change is a new installation job.

The biggest cost lever: wired or wireless

Calculation example: Picking zone with 200 compartments

• Wireless system: 200 modules at €15 = €3,000, plus radio gateways and commissioning approx. €5,000 → around €8,000 investment.
• Wired system: 200 modules at €150 = €30,000, plus electrical installation at €100 per compartment = €20,000, controller and cabling material approx. €5,000 → around €55,000, plus installation time during ongoing operations.

When does Pick-to-Light pay off? The ROI calculation

• Time savings: Four employees pick 300 items each per day. If the light signal saves just 5 seconds per pick (studies show up to one-third time savings compared to paper lists), that is 1,200 picks × 5 seconds ≈ 100 minutes per day. At €30 in total costs per hour: around €1,100 per month.
• Error costs: If the error rate drops from 0.3 percent to near zero, 3 to 4 picking errors are avoided per 1,200 picks daily. Even at a moderate €50 in follow-up costs per error (rework, returns, complaints), that is over €3,000 per month. In production-critical processes, where a missing part can stop the line, it is significantly more.

Hidden costs: Five questions you should ask every provider

1. What does ERP integration cost—project or configuration?
   ‍Custom development is the most common cost driver after the initial purchase. Even in-house development incurs significant costs.
2. What does a layout change cost?
   ‍Reconfiguring shelves or expanding your product range: with wired systems, this requires a service call every time; with wireless modules, it is just a matter of moving the units.
3. Am I locked into your hardware?
   ‍Hardware lock-in turns every expansion into a monopoly-priced purchase. Hardware-agnostic platforms keep competition open.
4. What happens with new use cases?
   ‍If you want to add eKanban or digital labels later, you end up paying for a second system with standalone solutions. With a platform, you can simply activate the new use case based on your existing hardware.
5. What is included in the license?
   ‍Updates, support, hosting—or is every item charged separately?

Start small: the pilot project

Frequently asked questions about Pick-to-Light costs