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Case Study

Replacing a Legacy Sorter

Robotic arm placing an item on a warehouse sorting line.

CUSTOMER SUCCESS STORY

Replacing a Legacy Sorter Without Missing a Single Shipment

INDUSTRY: Off-Price Retail, Apparel USE CASE: Store Replenishment Fulfillment BG SOLUTION: StrideTM Shuttle Sorter

replacing aging sortation

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

  • Their existing tilt-tray sorter was at the end-of-life.
  • It had become a single point of failure in the replenishment operation.
  • Outages were putting outbound throughput and service levels at risk.
  • The retailer needed to support rising store count and growing volume.
  • 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 the StrideTM Shuttle Sorter on a mezzanine alongside the legacy sorter, avoiding downtime during installation and ramp-up. Stride combines robotic and manual picking with orchestration software to improve SKU handling, labor efficiency, and scalability.

KEY ATTRIBUTES

  • Hybrid picking uses automated SKU eligibility routing to direct items in real time to either robotic or manual picking stations for optimal fulfillment efficiency.
  • Simulation-led design validates the system for 30% store growth, stress-testing performance and ensuring long-term scalability.
  • A flexible staffing strategy used simulations of peak and off-peak demand, along with store mix variations, to guide labor planning and resource allocation
  • Scalable architecture with a modular design enables phased expansion without requiring changes to core conveyance or system logic.

QUANTIFIED BENEFITS

smaller warehouse footprint
0 %
labor dependency reduction
0 %
downtime during installation
0

24/7/365 continuous support & optimization

AFTER GO-LIVE

After installation, the system was refined through close collaboration to boost efficiency and protect downstream operations.

  • Jointly managed ramp-up of robotic picking to validate SKU eligibility and build operator confidence in automated routing
  • Smarter staffing through orchestration software that directs operators across stations, balancing throughput and labor hours.
  • Deployed shuttle upgrades and divert sensor to improve sortation accuracy.
The result is a resilient fulfillment backbone that replaced a tilt-tray sorter without disruption and continues to deliver scalable efficiency gains, earning the customer’s trust to handle items the legacy sorter could not.

“We used to hold our breath every time the tilt-tray groaned. Now we have Stride – a system built for the long haul.”