CUSTOMER SUCCESS STORY | WAREHOUSE AUTOMATION SOLUTIONS
High-Volume Third-Party Logistics Provider Achieves $500K in Annual Savings with Regal Rexnord™ Warehouse Automation Solutions
150%
Increase in sortation throughput
99%
Sorting accuracy
$500K
Annual labor cost savings
Facing rising labor costs, order inaccuracies, and seasonal demand peaks, a leading 3PL provider turned to Regal Rexnord for a modular automated sortation system that increased throughput, improved sorting accuracy, and delivered measurable labor savings.
THE CHALLENGE
A leading 3PL logistics provider was facing rising labor costs and increasing order inaccuracies driven by a manual sortation process handling approximately 1,200 packages per hour. The existing operation could not scale to meet seasonal peak demand, resulting in shipping delays, customer complaints, and limited ability to flex capacity across regional sites.
THE SOLUTION
Regal Rexnord delivered a modular, automated sortation system designed to handle mixed parcel flows without manual intervention. The solution incorporated MDR conveyors, ModSort™ diverts, and an intelligent control system - including scanners - to automate sorting while seamlessly integrating with the warehouse management system. The compact, mobile design allowed the solution to fit within the existing footprint and be redeployed quickly across the customer’s regional 3PL locations as demand shifted.
MDR Conveyors
Move mixed parcel flows through the automated sortation system.
Scanners + Intelligent Controls
Automate parcel identification, routing, and sorting decisions.
ModSort™ Diverts
Route parcels accurately without pneumatics.
WMS Integration
Connect the sortation process to the existing warehouse management system.
SERVICES PROVIDED
✓ In-house factory acceptance testing (FAT)
✓ Mechanical and electrical installation
✓ Software commissioning
✓ Site acceptance testing (SAT)
THE BENEFIT
The system eliminated manual sorting touches, significantly increased peak capacity, and reduced maintenance requirements through a no-pneumatics design, cutting maintenance needs by 50%. The modular architecture enabled rapid deployment and flexibility without disruption to existing operations.
✓ Scaled throughput from approximately 1,200 to approximately 3,000 packages per hour.
✓ Improved sorting accuracy to 99%, supporting customer satisfaction and order quality.
✓ Redeployed four full-time employees to higher-value roles.
✓ Delivered $500,000 in annual labor savings.
✓ Responded faster to seasonal demand peaks without additional headcount.
A WINNING OUTCOME
150%
Throughput increase
$500K
Annual labor savings
4 FTEs
Redeployed to higher-value work
A TRULY UNIQUE PARTNERSHIP
One Solution, One Partner, One Source
An integrated automation solution combining products, engineering, integration, and service under a single trusted provider.
System-Level Design and Accountability
A holistic system approach ensuring seamless performance across mechanical, electrical, and digital components with one point of accountability.
Scalable, Configurable Automation
Modular design enabling fast redeployment, system expansion, and adaptation as operational requirements change.
Proven Performance in High-Demand Applications
Built on deep experience supporting high-throughput, mission-critical logistics environments with a focus on reliability and performance.
Optimize Your Sortation Operation
Talk to a Regal Rexnord warehouse automation expert to learn how modular sortation, MDR conveyors, ModSort™ diverts, and integrated controls can increase throughput and deliver measurable warehouse automation ROI.