Mass Merchandiser Expansion

The Client

Our client is one of America’s largest retailers of closeout merchandise and excess inventory.

The Challenge

Partnering since the beginning of the millennium, KPI has worked alongside the client as an extension of the company in pursuit of the right solution for its operations.

Initially, the client started with less than 50 stores, and now, they have expanded to over 500 stores, intending to service the entire United States. After outgrowing capacity in current facilities and strategizing to expand in the Northeast, KPI stepped in to build new, fully automated case pick facilities.

The Solution

KPI worked with this mass merchandiser to build a 655,000-square-foot distribution center in Lancaster, Texas. The new material handling system gives them increased efficiency and capacity to assist in delivering products to current stores and expanding further into the western US. The client is adding up to 45 stores per year.

To help save on transportation and shipping costs as well as increase customer satisfaction, building new distribution centers closer to the stores was the best option.

After having issues with side-by-side packages on the line, KPI installed the Fives Singulator that unscrambles and straightens packages as they move down the line.

Other features of the facility include:

• Intelligrated and Automotion conveyor in Unarco pick modules
• Deep full case pick modules
• Pick-to-light systems
• Voice pick systems

KPI will continue to provide innovative solutions and expertise during the client’s quest to achieve higher performance.

Solution Highlights:

• WCS software control system
• Slapper line induct area
• 180-case-per-minute conveyor system
• 8 to 1 merge conveyor systems
• 29-lane high-speed shoe sorter
• 28 fluid load truck loaders

The Value

• Increased efficiency
• Increased capacity and throughput
• Ability to achieve a max of 200 cases per minute