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Case Study

Modernizing Replenishment

Sort Controller Belt

CUSTOMER SUCCESS STORY

Modernizing Replenishment in a Brownfield Setting

INDUSTRY: Grocery & General Merchandise
USE CASE: Store Replenishment Fulfillment
BG SOLUTION: StrideTM Shuttle Sorter

Support rising demand without disrupting operations

THE CHALLENGE

An end-of-life tilt-tray sorter was threatening throughput and service levels. The retailer needed a scalable replacement with no operational disruption during deployment.

KEY CHALLENGES

  • Automation that worked with their people — not around them.
  • Needed to operate within the existing footprint.
  • Reduce manual touchpoints.
  • 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 its StrideTM Shuttle Sorter system directly into the existing warehouse layout. Instead of displacing infrastructure, the solution was designed to work with it – a truly seamless brownfield installation.

KEY ATTRIBUTES

  • Stride was designed to integrate with their legacy shuttle ASRS systems.
  • Modular semi-automated stations were installed in the manual put wall area while working around existing columns and equipment.
  • BG developed a custom integration with the existing software stack to minimize workflow disruption and avoid unnecessary change orders.

QUANTIFIED BENEFITS

pick productivity improvement
0 X
FTE reduction
0 %

24/7/365 continuous support & optimization

AFTER GO-LIVE

Deployment was just the start. Realizing the full potential of the integrated system required ongoing collaboration between BG and the customer. After overcoming initial challenges, joint efforts led to:

  • 10–15% throughput increase from logic tuning, software updates, and operational validation.
  • Successful WMS order cartonization upgrade to support business strategy shift.
  • Continuous support through ASRS software end-of-life transition.
Today, Stride is among the site’s most stable solutions, with expansion being actively considered.
“BG stuck with us through every stage — from early design to long-term optimization. Stride performs, and the relationship continues to grow.”