Pick-to-Light-system. The best solutions 2023


What elsecan a complex Pick-to-Lightsystem control and manage? Which additional functions should be included and which not? What does the LUCA standard package contain?

A Pick-to-Lightsystem consists not only of individual displays, but often includes other complex functions and components. We develop and deliver simple as well as very complex Pick-to-Light-systems. However, the exact design of the systems always depends on the customer's requirements. On the other hand, LUCA also offers some LUCA standard packages, which may be able to meet your requirements directly? Save money with LUCA standards!

We will answer all these questions in this article. We will not only give you a few tips, but also explain in detail the differences between the individual expansion stages and their possibilities.

Thanks to the LUCA-Server , our system can do much more than just turn the displays on and off. Take your time and read this article at your leisure.

At the end of the article you will find our FAQ about the Pick-to-Light system. Also subscribe to our newsletter and easily stay up to date.

What can a complex Pick-to-Light system control?

A Pick-to-Light system can not only switch the displays on and off itself, but also take over many other simple and complex functions in logistics or production. The displays and controllers do not take over any logical functions. All interfaces, the flow process and the whole control logic are implemented in our LUCA-Server . For this reason, we can offer and deliver both inexpensive LUCA standard packages as well as very complex and customized systems.

Connection of external devices and systems

The LUCA-Server provides a professional platform for connecting many external components and subsystems. Here is just an excerpt:

  • Barcode scanner (order start, article control, etc.)
  • RFID reader (article registration and employee registration, etc.)
  • Scales
  • Labelers and automatic packaging machines
  • Torque screwdrivers and measuring sensors (production and assembly stations)
  • LIN testers for car parts (Automotive)
  • Direct digital I/O interfaces (simple machines via optocouplers)
  • PLC controls

Thus, if required, any external device can be connected to our Pick-to-Light via the LUCA-Server .

LUCA standard package:
A direct connection of barcode scanners in a Pick-to-Light system is part of everyday life and is also included in the LUCA standard package. No matter if cable- or radio-bound. We use many scanners from well-known manufacturers for this purpose. Recently, hand-back scanners with a cuff have become very popular (e.g. ProGlove).

Here is our modern hybrid scanner(barcode and RFID) as a further development with a WiFi connection.

Back of the hand scanner - LUCA
This hybrid scanner can read all barcodes and RFID and communicate via Bluetooth or WiFi. A replaceable battery ensures continuous operation.

We will report on this robust WiFi scanner (with RFID option) in a separate article. If you have any questions, we are of course already at your disposal.

Complex processes made simple

We are specialists in material flow and picking systems. Thanks to the professional platform and open interface of the LUCA server, the creation of complex systems is also no problem for us.

Basically: anything goes!

Not only the connection to the HOST system, but also a direct control of many components belong to the functions of a Pick-to-Light system. However, an exact delimitation of the functions is hardly possible itself. For this many aspects like: Warehouse management, material flow, production control, assembly stations, other pick-by systems and much more are included.

Distribute tasks correctly

The overall system in a logistics or production consists of many individual components, whereby all of these systems have their own tasks. For this reason, the tasks should also be quite clearly defined:

Pick-to-Light-system controls the picking

However, the basis of this task here are the electronic pick lists sent by a warehouse management system (WMS) or production control system (PSS).

The recommended hierarchy:

System nameFunctions
HOSTOrder processing and commercial transactions
LVSWarehouse management: control of stocks, goods receipt, goods issue, inventories
MFS (MFR)Material flow control (only if conveyor technology is available)
Pick by systemsPicking and Multi-Order-Picking
PLCControl of the conveyor system and machines

What additional functions can a Pick-to-Light system perform?

Recommended additional functions:

  • Control of the part numbers
  • Serial number capture
  • Management for Multi-Order-Picking in a job batch
  • Multi-user management in one picking zone
  • Zero passage tests (together with LVS)
  • Direct weight checks with scales
  • Control of test equipment and simple machines (production)
  • Printing simple labels
  • Direct communication with robots and forklift control systems

Only conditionally recommended additional functions (mostly for small installations):

  • Assignment of the storage bins to the articles (mini LVS)
  • Management of sets (mini production)
  • Destination control (material flow control for diverting to the zones)

What functions should the other systems perform?

These superstructures may be Pick-to-Light in no case take over:

  • Complete warehouse management
  • Management and accounting of orders
  • Management of the picking orders
  • Direct control of machines and the conveyor system via I/O contacts
  • Printout of delivery bills and invoices
  • Shipping labeling

Common mistakes in the distribution of tasks ...

Almost all warehouse management systems (WMS) already have simple picking methods integrated (handheld or scanner). They sometimes also try to control the Pick-to-Light displays without a professional picking system. However, this is wrong and not recommended! After all, these systems are supposed to perform their own tasks and often do not have the flexibility and required response times to operate a complex Pick-to-Light correctly and in real time.

Pick-to-Light in the LUCA standard package

We will describe the topic in a separate article soon and copy a link for it here. Stay tuned and subscribe to our newsletters to not miss anything.


A Pick-to-Light can take over very simple or also very complex functions and tasks in a warehouse or in a production. The most important thing here is the correct distribution of tasks between the individual systems.

We are happy to support you during the planning phase to define the correct distribution of tasks in a complex pick-to-light system. Please also read: "How to plan a Pick-to-Light / Pick-to-Light system". If you have any questions, please contact us.


Which tasks can a Pick-to-Light system take over and which not?

- Part number control
- Serial number capture
- Management for Multi-Order-Picking in an order batch
- Multi-user management in a picking zone
- Zero-crossing checks (together with LVS)
- Direct weight checks (see also Pick by Weight)-
- Control of checking devices and simple machines (production)
- Printing of simple labels
- Direct communication with robots and forklift guidance systems

- Complete warehouse management
- Management and accounting of orders
- Management of picking orders
- Direct control of machines and the conveyor system via I/O contacts
- Printing of delivery bills and invoices
- Shipping labeling

Who can help me plan a complex Pick-to-Light system?

There are some planning offices that specialize in planning logistics facilities and production systems. The experts of LUCA Logistic Solutions support your planning very professionally.

Where can I request and purchase a Pick-to-Light system?

There are some Pick-to-Light providers on the market that have very good experience.
Pay attention especially to which BUS system is used there. The old solutions are based on an ASI bus, which was known from PLC control technology in the past. These providers are no longer in demand today.

Many years of experience in paperless order picking