The challenge

Serving the DIY-sector flexibly:

Smarter cross-docking by a logistics service provider, Willebroek (BE)

With space savings of more than 50%, a significant reduction in errors in the process and efficiency improvements in order picking, this logistics service provider is ready for further growth.

For one of its customers in the DIY sector, this logistics provider wanted to start cross-docking more intelligently. A sorting installation helps to distribute goods directly to the branches after arrival. The installation also sorts branch crates with collected orders. However, the fact that the collection itself could be a lot smarter and more efficient was the icing on the cake.

Robot warehouse

The solution

Goods to man

Shuttle racks and AGV robots

No more mezzanine floor with shelves between which the order pickers find their way, but 1100 moveable shuttle racks, together good for 25,000 picking locations. The racks move automatically thanks to 32 flexible AMR robots. Put- and Pick-to-Light and six workstations are used for inbound and outbound picking, where the pickers concentrate on picking instead of walking and searching.

1500 Units per hour

Branch orders are transferred from the shuttle racks into plastic crates. These go via the conveyors to the sorting installation and are distributed per branch. The installation has a capacity of 1500 units per hour, has 14 chutes, each representing up to 10 branches. Here the goods are distributed in roll cages or on pallets using Put-to-Light.


In the morning, the sorter processes the outbound crates of store orders. In the afternoon, it is ready for the cross-dock process. In this, incoming pallet loads are distributed directly at the sorter for the right store.

The result

Doubling: efficiency and space savings

Less walking, smarter working

With this Costo total solution, including a link to the ERP, the logistics service provider saves a lot of space. It now has more storage locations on less than 50% of the original floor space. Thanks to the goods-to-man principle, the maximum output of a collector is 300 lines per hour. That’s higher than before and with a smaller chance of errors. The space gain provides opportunities for the storage of other products. It increases the market opportunities for both the logistics service provider and its customer.

The double function of the sorting installation proves daily the convenience of automatic distribution and timely delivery to the branches of the DIY stores in the Benelux.

Meeting Costo Intralogistics


Contact one of our specialists

Would you like advice on the automation of your warehouse? Then get in touch.
Our team full of knowledge and experience will be glad to think along with you!

Leading innovations

Check our other cases!

Case Smyths toys (EN)

Retail and e-commerce combined in one warehouse. This was the result of an optimal focus on scalability, stock optimization and reducing the required m2.
The smart application and collaboration of WMS, ERP & hardware made this possible at Smyths Toys in Walsrode, Germany.

Smarter cross-docking at a logistics service provider

Order picking and cross-docking over the same sorter at a logistics service provider.