AutoStore Boosts Bergfreunde: 2-Year ROI and 288% Efficiency Gain

Source: Element Logic

Bergfreunde is an online retailer specializing in outdoor and mountain sports equipment. Founded in 2006 and based in Kirchentellinsfurt, Germany, Bergfreunde has grown significantly over the years, with annual turnover increasing from 18 million to 242 million euros since 2013. The company’s online store offers more than 150,000 items from over 750 brands.

Bergfreunde inaugurated a 10,000 m² (108,000ft²) logistics center in Germany in August 2016, using the AutoStore system empowered by Element Logic. Originally designed for 1,800 m² (19,400 ft²), the system has been expanded several times since then. Today, the company has almost tripled picking efficiency from 45 to 175 picks per hour, and reduced lead time from order to shipment to under three hours.

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The Challenge: Scale Operations for Rapid Growth

It was challenging for Bergfreunde to maintain efficiency and scalability during a period of substantial growth, with yearly sales climbing by approximately 30% in both 2017 and 2018. The existing manual shelf storage system proved inadequate in the face of rising demand, managing only 45 picks per hour.

Bergfreunde needed an efficient and scalable solution to address expanding operational requirements and simultaneously improve employees’ working environment.

The Solution: Large-Scale Automated Storage and Retrieval System

The AutoStore system at Bergfreunde's logistics center has significantly improved order fulfillment capabilities. There are 80 Robots traversing the 3,000 m² (32,000 ft2) grid system, managing 94,000 Bins stacked in 16 levels, with 21 Ports for moving items in and out of storage. Over 100 employees, working in two shifts, process up to 200,000 items per workweek, handling incoming goods, returns, and shipping.

This setup enables Bergfreunde to handle up to 15,000 orders on peak days. Importantly, the lead time from customer order to shipment has been reduced to under 3 hours, substantially enhancing customer satisfaction. The recent introduction of the AutoStore CarouselPort 3.0 series has further improved ergonomics, reducing employee fatigue and boosting overall productivity.

Key Benefits: Efficient, Scalable, Future-Ready Operations

AutoStore has transformed Bergfreunde's warehouse into a highly efficient, adaptable space, maximizing its use for current and future needs. This high-density, energy-efficient storage solution streamlines the entire picking and packing process, and its modular design allows for easy expansion without major disruptions.

• Return on capital is assured, with the investment recouped within two years
• Throughput has increased with a 288% increase in the picking rate
• Lead time has reduced significantly
• Scalability is assured
• Energy efficiency is improved
• Employees’ working environment has been enhanced

Today, Bergfreunde's warehouse stands as one of the most advanced automation systems in Europe. The transition from traditional warehousing to an efficient, automated system has addressed the critical challenges of rapid growth and the need for scalable operations.

Growth Potential Secured

Bergfreunde achieved full return on investment for its AutoStore and warehouse automation systems in less than two years, highlighting the solution's remarkable efficiency. The company's plans to add 10,000 m² (108,000 ft2)to its logistics facilities will support its ongoing expansion, allowing for further improvements in operational capacity and customer service quality.

The seamless integration of AutoStore into Bergfreunde's logistics operations has not only met, but exceeded the company's expectations, setting a new standard for efficiency and scalability.

With AutoStore, Bergfreunde has overcome its immediate challenges and positioned itself for continued success in the competitive e-commerce market. As this retailer continues to grow and evolve, AutoStore provides a solid foundation for ongoing success.

Project Specifications

• Implementation type: Brownfield (existing site)
• Robots: 80 Robots
• Workstations (Ports): 21 CarouselPorts
• Bins: 94,000 Bins
• Integration partner: Element Logic