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Case Study

Expanding Automation

CUSTOMER SUCCESS STORY

Expanding Automation at Scale

INDUSTRY: Off-Price Retail
USE CASE: Store Replenishment Fulfillment
BG SOLUTION: Stride™ Shuttle Sorter

Setting the standard for next generation fulfillment

THE CHALLENGE

    As one of the network’s centers of  operational excellence, this distribution site was tasked with validating  automation that could serve as a  blueprint for future facilities.

KEY CHALLENGES

  • Technology capable of replacing legacy tilt-tray sorters.
  • Automation flexible enough to support multiple fulfillment models for regional and national replenishment.
  • The replacement had to meet current capacity needs and scale for future growth.
  • The new system had to be deployed without disrupting live operations.

seamless scalable sortation deployment

SOLUTION

    Berkshire Grey deployed an initial seven Stride Shuttle Sorter stations on a mezzanine to support regional operations. The installation ran in parallel with the tilt tray, ensuring no disruption to ongoing fulfillment. Stride delivered strong results, and its success prompted a strategic expansion to seventeen stations.

KEY ATTRIBUTES

  • Expansion more than doubled capacity: through modular stations, enabling the replacement of the legacy tilt-tray sorter
  • Ability to merge workflows onto one platform: so both regional and national replenishment could be managed within the same automated system.
  • Modular growth without disruption: enabled additional stations to be added seamlessly, avoiding costly rework or downtime.

QUANTIFIED BENEFITS

throughput per labor hour increase
0 %
footprint reduction
0 %
downtime during installation
0

24/7/365 continuous support & optimization

AFTER GO-LIVE

    The expansion proved the strength of the platform, and post-deployment collaboration has focused on unlocking its full potential.

  • Jointly optimizing merged workflows to ensure regional and national replenishment could run seamlessly within one automated system.
  • Smarter employee staffing with software that dynamically matches operators to stations based on real-time parameters.
  • Expansion-ready design allows further capacity to be added in phases, deferring capital investment until demand is proven.
This site now operates as a scalable innovation hub — a proven model for replacing legacy sorters and expanding capacity with minimal disruption.
“What started as a pilot is now the model for growth – expansion without disruption and a clear path for the future.”