Bin insert using Pio App

After your Pio system has been installed and approved by Pio, you can start the bin insert process. It takes some time to insert all the bins in your Pio grid, so make sure you have booked enough time and people to do it. The time it takes to insert all the bins into the system varies based on several factors like the number of robots and grid height. However, as a general guideline, it's safe to estimate that two people working together at a single port can typically insert between 200 to 300 bins within an hour.

Please note that you cannot insert bins and products simultaneously. However, you can add the bin dividers before inserting bins into the system in order to get up and running faster.

This video will guide you through the process of adding empty bins in Pio. Begin by watching the video, and then explore additional step-by-step information below the video for further clarification.

Topics covered in this article

Bin insert process
Unpack bins
Check bins for potential damage
Add bin dividers
Add bin labels
Scan bin label and add the bin in Pio 
Manually enter bin ID


To add new bins to Pio, you'll need: 

  • hand scanner (installed and ready to use) 
  • iPad with the Pio App (confirm with Pio staff that the app is connected to your system)
  • bin test-jig 
  • empty bins
  • bin labels 
  • bin dividers

Start the preparations by removing the port furniture: 


Use some empty bins to set up an assembly line: 

Bin insert process

We recommend assigning individual tasks to 3-5 people for efficiency. Example of how the tasks can be organized:

  • one person unpacks bins
  • one checks bins for damages
  • one adds bin dividers
  • one adds bin labels, scans them and inserts the bins into the grid

Unpack bins

If you have received the bins before you actually start to insert them into the system (and you have space for it), open the wrapped foil around the bin pallets the evening/day before bin insert. This might help the bins to recover from possible transport deformations.

Remove all shipping labels, plastic grippers and black plastic nobs from the bin pallets. 

Check bins for potential damage

The bins might have been damaged in packing or transport, so it's crucial to check all your bins before inserting them into your Pio grid. A damaged bin within the grid can lead to significant problems for the entire system!

Check the bin for any damages:


bin_insert6.jpg      bin_insert7.jpg      bin_insert8.jpg ​​​​​​​

Check the bin for deformation:

bin_insert9.jpg    bin_insert10.jpg

Make sure the bin meets its size specifications by using a bin test-jig that has been provided to you. Place a bin on the jig. If the bin fits the test-jig you can insert the bin in the system.


If the bin does not fit the test-jig, it is smart to set the bin on the side and let them rest a few days. Sometimes the deformation can only be temporary after tight packaging and the bins can straighten out over time. 

CAUTION! Bins that do not pass the quality check must be set aside!

Add bin dividers

Storage capacity in bins can be optimized by using bin dividers, There are two types of dividers that can be used to configure bins into 2, 4, 8 or 16 compartments. 

When inserting the bin dividers, make sure that the notches are facing down: bin-divider-notches down.png

You can find a more extensive guides on bin dividers here: How to maximize storage capacityBin dividers and How to insert bin dividers 

Add bin labels

Next step is to add a bin label to each bin. Bin ID is used to identify each bin in the grid. The stickers have been delivered to you during Pio installation.

Place the bin label on the longest side of the bin. The number should be facing you.


Scan bin label and add the bin in Pio 

Place the bin into the port if you haven't done it already. Use Pio app to add the bins into the grid. Note that you have to be logged in as Pio Manager or Admin in order to add new bins to the system. 

Open 'Configure bins' and choose option 'Add new bins':


Select the correct bin layout and scan the label: 


A counter on the right side of the bin insert-screen helps you to keep track of how many bins of the chosen layout has been added to the system. You can also see the total number of this layout currently in the grid. On the top of the screen you can see your current speed of adding bins into the system. 


The bin will be collected from the port by a robot as soon as it is scanned and registered in the app. You will see a success message confirming that the bin has entered the grid.


Continue to insert bins into the port and scan the barcodes by repeating the previous steps until you need to change bin layout or take a break.


Choose 'Back to homepage' if you are finished with bin insert, or click 'Add more bins' if you want to start a new session with adding another bin layout.

Manually enter bin ID

If the barcode label is not recognized by the hand scanner, or the hand scanner is not available, you can enter the bin ID manually. Use the option in upper right corner (next to Your user account) to open the popup where ID can be entered. Choose 'Add bin' to register the bin and send it into the grid.


Once you've successfully added bins to the system, you can begin the process of storing products. Find further information on the storing process here: How to store products in Pio

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