CUSTOMER SUCCESS STORY | WAREHOUSE AUTOMATION SOLUTIONS
Global E-Commerce Fulfillment Provider Doubles Order Capacity with Regal Rexnord™ Warehouse Automation Solutions
Facing a post-COVID surge in order volumes and a limited facility footprint, a global e-commerce retailer turned to Regal Rexnord for a compact, high-throughput SLAM/ASL solution — delivering fully automated parcel sorting, improved label accuracy, and measurable warehouse automation ROI.
2x
Order capacity
1,500
Packages per hour (pph) throughput
15' x 30'
Compact system footprint
THE CHALLENGE
A global e-commerce retailer needed to expand capacity and improve efficiency across its fulfillment center automation and distribution center automation operations during the post-COVID surge in order volumes. The company sought scalable warehouse automation solutions to support growing demand, but a limited facility footprint constrained expansion. At the same time, the operation required improved label accuracy, enhanced parcel handling automation, and a transition from manual hand scanning to a fully automated process capable of supporting warehouse sortation automation, automated parcel sorting, and high-volume package processing. The retailer needed a compact automated sortation system that could increase throughput while delivering measurable warehouse automation ROI.
THE SOLUTION
Regal Rexnord deployed a comprehensive logistics automation system featuring a SLAM/ASL solution that integrated dual induction zones, multi-scan tunnels, automated label application, and a ModSort® divert and transfer module. Designed to support warehouse conveyor automation and parcel sortation system requirements, this compact, high-performance solution improved read accuracy and enabled seamless package flow throughout the facility. Ten parallel SLAM lines were installed to create a high throughput sortation system capable of handling rapidly increasing order volumes. The solution also incorporated automated no-read handling through reject stations, eliminating the need for additional pneumatics while enhancing overall automated parcel sorting efficiency and system reliability.
Dual Induction Zones
Merged induction lanes feed parcels into the parcel sortation system for continuous, high-volume flow.
Merged induction lanes feed parcels into the parcel sortation system for continuous, high-volume flow.
Multi-Scan Tunnels
Multi-angle scanning improves read accuracy and supports reliable automated parcel sorting.
Multi-angle scanning improves read accuracy and supports reliable automated parcel sorting.
Automated Label Application
SLAM (Scan, Label, Apply, Manifest) processing replaces manual hand scanning.
SLAM (Scan, Label, Apply, Manifest) processing replaces manual hand scanning.
ModSort® Divert & Transfer
Compact, no-pneumatics divert module enables seamless warehouse conveyor automation.
Compact, no-pneumatics divert module enables seamless warehouse conveyor automation.
THE BENEFIT
The SLAM solution enabled the customer to handle significant year-over-year volume growth while reducing manual touchpoints. Integrated scanning, labeling, and automated reject routing reduced labor requirements and improved process consistency.
✓Scaled throughput to 1,500 packages per hour within a compact 15' x 30' footprint.
✓Improved label accuracy with automated exception handling and merged induction lanes.
✓Reduced headcount by automating repetitive scan, label, and sort tasks.
✓Enabled faster, more consistent fulfillment through end-to-end parcel handling automation.
✓ Delivered scalable warehouse sortation automation designed for future volume growth.
A WINNING OUTCOME
2x
Order capacity, scaling with demand
1,500 pph
High throughput sortation system
↓ Labor
Reduced headcount via automation
One Solution, One Partner, One Source
An integrated automation solution combining products, engineering, integration, and service under a single trusted provider.
An integrated automation solution combining products, engineering, integration, and service under a single trusted provider.
Scalable, Configurable Automation
Modular design enabling fast redeployment, system expansion, and adaptation as operational requirements change.
Modular design enabling fast redeployment, system expansion, and adaptation as operational requirements change.
System-Level Design and Accountability
A holistic system approach ensuring seamless performance across mechanical, electrical, and digital components with one point of accountability.
A holistic system approach ensuring seamless performance across mechanical, electrical, and digital components with one point of accountability.
Proven Performance in High-Demand Applications
Built on deep experience supporting high-throughput, mission-critical logistics environments with a focus on reliability and performance.
Built on deep experience supporting high-throughput, mission-critical logistics environments with a focus on reliability and performance.
Optimize Your Fulfilment Operation
Talk to a Regal Rexnord warehouse automation expert to learn how SLAM/ASL sortation, ModSort® diverts, and logistics automation systems can increase throughput and deliver measurable warehouse automation ROI.