Evolving a DC to Enable Fulfillment

Build for today and tomorrow.

THE CHALLENGE

Reconfigure distribution for
omnichannel fulfillment

THE SOLUTION

Elemental expandability, modular
adaptability and low-touch logistics

Rapidly transition to low-touch omnichannel fulfillment

Keeping up with evolving business needs and consumer demands in food retail can be challenging. How can you predict when you will need added eGrocery capacity? This business case describes how a new regional distribution center (DC) can be designed to deliver the epitome of low-touch distribution efficiency today, then accommodate fulfillment with minimal disruption to the existing DC.

The extraordinary flexibility is enabled by:

  • Modular autonomous robotics
  • Intelligent logistics software
  • Sector-specific expertise

Invest in what you need now, then expand or evolve for what’s next. The entire system is software driven, which allows for rapid configuration and reconfiguration, simpler and lower-cost operation and a more resilient fulfillment network.

Distribution center scene featuring KNAPP food retail automation solutions optimizing freshness, accuracy, and high‑volume throughput while supporting efficient, sustainable grocery fulfillment.

Here’s a breakdown of the high-speed, low-touch store replenishment workflow — from goods in to goods out.

  1. Receiving, Induction & Staging — Master data article attributes, weights and dimensions of incoming shipments are automatically scanned, validated and prepared for staging, storage and automation.
  2. Reserve Storage — Inventory not immediately needed is sent to a high-density, unit load ASRS. At the same time, inventory needed for short-term orders is sent for depalletizing.
  3. Depalletizing — Automated depalletizing stations remove cases from pallets. Intelligent logistics software identifies fast and slow-moving items to determine where they’re stored in the shuttle system. Vision technology confirms items and counts are correct.
  4. Order Storage, Retrieval & Sequencing — Cases and individual items arrive at the shuttle system. Software determines where they’re stored, so they can be sent in a precise sequence to the robotic palletizer for enhanced stability and store-friendly delivery.
  5. Packing & Wrapping — Like a 3D puzzle, a fully-automated robotic palletizer assembles delivery-friendly, mixed pallets with unparalleled speed. The robot handles multiple cases per move, accommodating both large and small orders and different types of case units. Auto wrapping of pallets combines two processes in one seamless operation.
  6. Pallet transport — Wrapped pallets are conveyed to an automatic labeler, which applies a unique license plate to each outbound pallet. Pallets are then transported to the shipping dock by autonomous mobile robots.
  7. Shipping & Transportation — The software-driven system manages delivery routing, optimization and tracking during shipping.

Adaptability Enablers

  • Simultaneous workflow orchestration
  • Autonomous robotics
  • Elementary expandability
  • Modular system design
  • Support for two workflows in one shuttle system
Pick-it-Easy Robot handling groceries in a food retail environment, demonstrating AI‑driven picking accuracy, gentle item handling, and efficient automation for high‑volume supermarket fulfillment.

From DC to Omnichannel Fulfillment

When digital sales double and then double again, the DC can rapidly accommodate fulfillment of eGrocery orders. That’s because all of the core automation technology has elemental expandability.

Robots and workstations are easily integrated into the existing facility. So are shuttles. The system is modular. Just add aisles as needed. Then, drop shuttles in and they self-configure.

The shuttle system handles both instore replenishment and fulfillment of online orders. The ability to automate two independent workflows in the same system is unique in the industry.

Simultaneous Action Across the Facility

As store replenishment pallets go to depalletizing, eCommerce items go to new decanting stations. Software ensures people, processes and technology are in lockstep as inventory is moved into the shuttle system.

Automated full-case picking, manual each picking and robotic each picking all happen simultaneously. AI-enabled robots learn continuously and share learnings with other robots in the facility or across the rest of the supply chain.

As store replenishment orders go to the robotic palletizer, online orders go to boxing and labeling. The system begins building boxes to order size and weight requirements as soon as the order enters the fulfillment system. That means they’re ready when the items arrive.

Achieve high performance with low-touch operations

When everything is integrated, interconnected and intelligent, retailers can achieve a higher level of automation for low-touch operations that maintain an exceptional customer experience.

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