How much does a pick-to-light system cost? Prices, cost drivers, and a calculation example

Anyone searching for pick-to-light prices will mostly find one thing: "Contact us for a quote." Yet, the question can be answered much more concretely. In this article, we break down the cost components of a pick-by-light system, identify the factors that truly drive the price, provide an example investment calculation for a picking zone, and explain when the system pays for itself.

The short answer: Hardware typically costs between 80 and 250 euros per storage bin, depending on the display type. However, the biggest price difference doesn't come from the modules, but from the installation: wired systems require electrical work at every single bin, whereas wireless radio systems eliminate this cost entirely. Typical projects pay for themselves in under twelve months.

The five cost components of a pick-to-light system

1. Hardware per bin. The module at the storage bin is the most visible component: ranging from a simple LED indicator with an acknowledgment button to modules with quantity displays or ePaper screens. Market prices typically range between 80 and 250 euros per bin, depending on the features. The rule of thumb: the more information you want displayed directly at the bin (quantity, item, order), the higher the module price.
2. Infrastructure and installation. This is where the market divides. Wired systems require power and data lines at every bin: cable ducts, distributors, controllers — and an electrician. Depending on the shelving situation, this can easily add 50 to 150 euros extra per bin, plus downtime during installation. Wireless systems replace this with a few wireless gateways: the modules are mounted to existing shelves and are ready for operation.
3. Software and license. Traditionally a one-time license with a maintenance contract, or modern SaaS subscriptions including updates, support, and hosting. The SaaS model shifts costs from capital expenditure to operating expenses — important for comparing offers: always compare the total cost of ownership over three to five years.
4. Integration. The system must receive orders from an 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 a simple configuration.
5. Implementation and operation. Process analysis, pilot setup, training — and during operation, batteries or power, occasional module replacements, and adjustments when the product range changes. The latter point is often underestimated: with wired systems, every layout change is a new installation project.

The biggest cost lever: wired vs. wireless

Calculation example: Picking zone with 200 bins

• Wireless system: 200 modules at €150 = €30,000, plus wireless gateways and commissioning approx. €5,000 → around €35,000 investment.
• Wired system: same modules €30,000, plus electrical installation at €100 per bin = €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 a total cost of €30 per hour, that is around €1,100 per month.
• Cost of errors: If the error rate drops from 0.3 percent to near zero, 3 to 4 picking errors are avoided daily out of 1,200 picks. Even at a moderate cost of €50 per error (rework, returns, complaints), that is over €3,000 per month—and significantly more in the automotive industry, where a missing part can stop the entire line.

Hidden costs: These five questions should be asked to every provider

1. What does ERP integration cost — is it a project or a configuration? Custom development is the most common cost driver after the initial purchase.
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 a simple task of moving the units.
3. Am I tied to your hardware? Hardware lock-in turns every expansion into a monopoly-priced purchase. Hardware-independent 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—on a single platform, you simply activate the new use case.
5. What is included in the license? Updates, support, hosting—or is every item charged separately?

Start small: the pilot

Frequently asked questions about Pick-to-Light costs