Leading 3PL, Arvato uses automated systems and software from KNAPP to process up to 5,500 orders per hour for beauty giant, Douglas Group.
Arvato relies on an automated intralogistics solution to fulfil omnichannel orders for the premium beauty brand, Douglas. Cosmetics, perfumes, skincare and hair care products are distributed from Arvato’s facility in Hamm, Germany, to online customers and retail stores across Germany, Austria and Switzerland.
Consolidating six former warehouses into one central facility, the Hamm distribution centre features automation from KNAPP, which enables Arvato to process up to 5,500 orders per hour for same-day and next-day delivery.
Evo Shuttle store
At the heart of the solution is KNAPP’s Evo Shuttle storage and retrieval system. Featuring 550 shuttle robots serving 132,000 storage locations across 22 aisles and 25 levels, this is the world’s largest shuttle solution in the cosmetics sector. The Evo Shuttle system handles almost all of the 70,000 SKUs at the warehouse, storing them double-deep for optimal storage density.
At goods-in, there are 28 decanting stations and KNAPP’s MultiScan system. Dimensions, weight and fragility are recorded for unknown items quickly and reliably, transmitting the information directly to the warehouse management system.
Ergonomic order picking
The 32 ergonomic goods-to-person workstations from KNAPP’s Pick-it-Easy Evo series allow employees to access two source containers and four order cartons simultaneously. The system at Hamm also includes 36 pick-to-light stations for manual picking (12 for pallet picking and 24 for sample picking), automatic carton-erectors, three cross-belt sorters, automatic document-insertion machines and intelligent conveyor systems.
Right-size packaging
Sustainability is enhanced by the choice of nine different sizes of carton for the B2C orders to be picked into. In addition, the height of these cartons is reduced during the automated carton-closing process in order to ship as little air as possible. This ensures that transport vehicles are optimally filled, thereby reducing the number of deliveries, saving costs and minimising carbon footprint. The use of right-size packaging technology is particularly valuable in a cosmetics warehouse, due to the small and lightweight nature of many products.
Powerful software
The software powering the solution was also supplied by KNAPP. This includes the company’s KiSoft platform to regulate the system workload and control the interaction of manual and automated areas, and KiSoft Analytics to enable Arvato to monitor system data and detect trends.
Lifetime support
The solution is supported by a team of resident KNAPP engineers, who make sure the system is always performing as it should. They take care of maintenance tasks with the help of KNAPP’s digital service solution, KiSoft CMMS, which helps Arvato in its decision making in terms of servicing and spare parts management.
Proven partnership
Since 2011, Arvato and KNAPP have worked together to implement numerous systems for customers in the technology, fashion, beauty and healthcare industries. “KNAPP supports us in attaining our strategic goals with their future-oriented logistics solutions,” says Sebastian Altrogge, Key Account Manager for Arvato.
KNAPP has provided tailored automation solutions for other 3PLs – including DSV, Radial and Hermes Fulfilment – as well as many brands in the beauty sector, including Boots, L’Oréal, LVMH, Kicks, ICI Paris and Amore Pacific.
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