Robotic Sortation System Implementation Case Study

This case study details the implementation of a robotic sortation system at a distribution site recognized as a center of operational excellence. The objective was to validate automation technologies that could replace legacy tilt-tray sorters and establish a new standard for fulfillment infrastructure. The facility operates under both regional and national replenishment models, making it an ideal candidate for flexible automation solutions. Berkshire Grey deployed seven Robotic Product Sortation stations, which were installed without disrupting ongoing operations. The initial success led to an expansion to seventeen stations, effectively more than doubling capacity. The system allows for the merging of workflows onto a single platform, facilitating seamless management of both replenishment models. Post-deployment collaboration has focused on optimizing workflows and staffing, ensuring efficient operations. The design of the system supports modular growth, enabling further capacity additions while minimizing disruption and deferring capital investment until demand is confirmed.