The Challenge
Efficient, Mixed-SKU Order Fulfillment in Cold Storage
Operating in refrigerated conditions introduced significant process and ergonomic hurdles. The customer needed an automation system capable of:
- Picking full case layers from stocking pallets
- Building mixed-SKU order pallets quickly and accurately
- Buffering partial pallets while awaiting additional SKUs
- Fitting the automation into a 65 × 32 ft footprint
MWES was selected for its ability to deliver AS/RS buffering with robotic layer pick logic integrated into an existing facility.
The Solution
Gantry Layer-Picking Robot & AS/RS Buffer Integrated with WMS
MWES deployed a turnkey automated order handling system featuring:
- A gantry-mounted robot capable of picking entire case layers (up to 550 lbs) at once
- A second robot tasked with pallet and slip-sheet handling
- AS/RS buffer racks staging up to 56 pallets while orders are in progress
- WMS-linked control logic for order sequencing and SKU tracking
- Automatic stretch wrap and labeling once pallets are complete
This layered messaging system delivers end-to-end automation from inventory pallet to palletized order build—minimizing manual work and enabling high throughput in cold storage.
Combining AS/RS buffering with a robotic layer picker and WMS-based sequencing, MWES delivered a cold-storage order fulfillment cell that operates reliably and efficiently in a tight footprint.
The Results
120 Layer Picks/Hour, Space & Labor Optimized Fulfillment
The solution provided substantial operational improvements:
- Batch throughput of approximately 120 layer picks per hour
- Storage and order build functionality condensed into ~65 × 32 ft of floor space
- Support for mixed-SKU orders with up to 56 partial pallet buffers
- Minimized physical labor and improved ergonomics in cold-store conditions
By integrating robotics, WMS logic, and AS/RS buffering, MWES enabled accurate, fast, and scalable pallet order fulfillment in a cold-storage environment—reducing labor dependency and preserving space.
