Research and Development

At Tornado, research and development are at the heart of everything we do. Our diverse R&D capabilities span many industries, and we are always open to new enquiries for bespoke projects that require research and development. From optimising warehouse operations to enhancing customer-facing technologies, we’re passionate about developing innovative systems that deliver measurable results.

At Tornado, we don't just provide solutions; we create them. Our R&D efforts ensure your business stays ahead of the curve, with technology that adapts to the ever-evolving landscape of automated storage and logistics. With Tornado, you gain a partner who is committed to constant innovation, ensuring that your systems remain scalable, efficient, and ready for future growth.

Explore how Tornado’s research-driven approach can help your business.

Software integration & logistical efficiency algorithms

We specialise in developing advanced middleware and legacy system integration solutions that bridge the gap between modern automated storage systems and your existing IT infrastructure. Our R&D team is dedicated to ensuring that your legacy systems, whether older ERP platforms or cutting-edge cloud solutions, work seamlessly with our state-of-the-art storage systems. We focus on innovating solutions that ensure your automation and software are fully integrated, providing flawless communication and data exchange across platforms.

Our commitment to R&D doesn’t stop there. We constantly enhance and refine our logistical efficiency algorithms to optimise every aspect of your operations. By utilising real-time data, our intelligent algorithms continuously improve stock placement, picking processes, and overall workflow management. These advancements allow us to optimise your warehouse capacity, streamline product flow and align with demand forecasting, helping your business make data-driven decisions that improve operational efficiency, reduce costs and enhance customer satisfaction.

Case study

Automated Storage & Collection Retrieval System (AS/CRS)

At Tornado, we are constantly pushing the boundaries of innovation. Our Automated Storage & Collection Retrieval System (AS/CRS) began as a research and development project with a vision to revolutionise how businesses manage and retrieve customer orders. After extensive testing, prototyping, and optimisation, we’ve created a solution that sets new standards in automated storage and logistics efficiency.

This system stores customer orders in trolleys, designed to be accessed anytime, day or night, either by warehouse personnel or by the customer themselves. Through vertical storage, the AS/CRS maximises space and enhances operational efficiency, providing faster retrieval times and optimising floor space. Our R&D team continuously improves the machine’s design to ensure the highest levels of productivity and flexibility for our customers.

Two machine options

Assisted System

  • Filled and emptied by warehouse personnel

  • A goods-to-warehouse-operative model supporting faster picking with minimal manual interaction

Automated System

  • Filled by warehouse personnel, emptied directly by customers

  • Allows customers to retrieve their orders independently, offering an efficient goods-to-customer experience within the Click and Collect model

R&D innovations

Space Efficiency – The system uses vertical storage to achieve up to 60% space savings compared to traditional storage methods, enabling you to make better use of your warehouse real estate.

Speed – The AS/CRS improves order picking times by providing quick, easy access to customer orders. By leveraging cutting-edge algorithms, we continuously fine-tune the retrieval speed and accuracy.

Custom Software – Alongside the hardware, we developed in-house stock management software that integrates seamlessly with your existing systems. This ensures smooth data flow and improves operational efficiency from order placement to collection.

    • 5-level system: Stores up to 58 trolleys or tote boxes

    • 6-level system: Stores up to 70 trolleys or tote boxes

    • Multi-Level openings

    • Further customisation available dependent on customer needs

Our R&D capabilities allow us to tailor the AS/CRS to meet your exact requirements

Through ongoing testing and software development, we ensure that our system integrates flawlessly with your existing infrastructure (including ERP systems like SAP) and can be hosted on platforms like AWS, Azure, IBM Cloud or on premises.

Our R&D efforts ensure that the Automated Storage & Collection Retrieval System is not only a state-of-the-art product but also a long-term asset, driving operational efficiency, reducing costs, and enhancing customer satisfaction. With remote monitoring, 24/7 technical support, and seamless integration, we empower businesses to stay ahead of the curve.

Case study

Goods Flow Manager Kiosk for Logistics Operations

Tornado was approached by a global logistics company with a challenge: streamline their goods flow and eliminate the inefficiencies of paper-based processes. The company needed a solution that would ensure seamless transitions between collections and deliveries, reducing downtime and speeding up operations.

Our R&D team developed an innovative paperless goods flow system utilising our kiosks, allowing drivers to quickly access and print the required customs paperwork at the point of exit. This solution not only expedited the drivers' journey but also ensured that no time was wasted waiting for necessary documentation.

To further enhance operational efficiency, we implemented a real-time monitoring dashboard that alerted technicians whenever paper, ink, or barrier systems were running low or malfunctioning. This early detection system allowed for immediate action to be taken, minimising costly on-the-job downtime and ensuring that logistics operations continued without interruptions.

  • Additional innovations included the use of QR codes on-site, which provided staff with access to troubleshooting videos. This empowered the staff to resolve minor issues, such as paper jams, independently, keeping operations running smoothly without the need for technical support.

    Our custom-made reports and 24/7 monitoring system also gave the company valuable insights into their daily operations. With this data, they were able to fine-tune their processes, optimise workflow, and gain a clearer understanding of their overall business performance.

    This project highlights Tornado’s ability to innovate and develop tailored solutions that enhance operational efficiency, reduce downtime, and provide real-time insights—key benefits for any logistics operation aiming to stay ahead in a fast-paced industry.

Case study

Order & Collection System for a Fast food Restaurant Chain

An independent chain of fresh and fast food restaurants in London approached Tornado to streamline their ordering and collection processes. Their goal was to enhance the customer experience by speeding up order fulfilment and enabling quicker collection.

Our R&D team developed a custom kiosk solution that integrated multiple payment methods, including cash, card, Google Pay, and Apple Pay, allowing customers to place orders and make payments quickly. The kiosks were designed to handle multiple orders at once, enabling customers to collect their food as soon as it was ready.

To ensure the system was flexible and adaptable to changing needs, we integrated a dynamic software solution that allowed the restaurant to easily customise menus for specific days, times, or special offers. This functionality gave the restaurant the ability to update the kiosk interface as needed, ensuring that promotions or menu changes were reflected in real-time.

  • Additionally, our system included a shift-based reporting feature, which provided real-time analysis of the funds required in each kiosk. At the start and end of each shift, these reports helped restaurant staff manage cash flow efficiently. By analysing trends from these reports, we were able to predict peak periods, such as busy Friday or Saturday nights, and ensure the machines never ran short of change.

    This project demonstrates Tornado's ability to develop customised, flexible, and efficient solutions that improve operational workflows and enhance customer experiences, all while providing valuable data insights for better decision-making.

Case study

Secure Kiosk Solutions for a British Bingo Hall

As part of our ongoing commitment to research and development, Tornado was approached by a popular British Bingo Hall with a unique challenge: create a secure, user-friendly kiosk system that could handle membership and Clubcard points while ensuring safety and privacy for all customers—especially those who may be vulnerable.

The task involved integrating their existing loyalty programs into the kiosks while maintaining the highest security standards. Our solution had to protect customers' sensitive data during every interaction, ensuring their information was kept secure before, during, and after use.

  • To meet these needs, our R&D team developed an intelligent dashboard that provided real-time updates and notifications for users. This dashboard could track balance checks, top-ups, and alert users to any potential fraudulent activity, offering immediate notifications if an issue was detected. We went further by designing the system to identify situations where a vulnerable customer may action unusual transactions and gently intervene.

    Given the variety of regulations in different regions, including specific rules around customer security, our R&D team also ensured that the kiosks could be easily adapted to comply with both global and local security standards. We made sure that all the necessary security updates were integrated seamlessly, allowing the Bingo Hall to maintain compliance with changing regulations and safeguarding their customers.

    This project demonstrates Tornado’s ability to deliver custom, secure, and functional kiosk solutions that integrate with existing loyalty programs while prioritising customer safety and compliance with industry regulations.