Dense Storage, Speed, and Efficiency for Electrical Wholesale Distributor

Adalbert Zajadacz GmbH & Co. KG is a leading electrical wholesale distributor, employing more than 700 people across 27 branches. To meet rising customer demands for overnight electrical component delivery across Hamburg, Zajadacz needed to automate and modernise their warehouse. The company chose AutoStore, empowered by AM Logistic Solutions, to improve efficiency, accuracy, and throughput, and to maximize their limited warehouse space.

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The Challenge: Meeting Hamburg's Overnight Delivery Demands

Zajadacz delivers electrical components overnight to customers across the greater Hamburg area, requiring a logistics system that ensures speed, accuracy, and reliability. With growing order volumes and increasing customer demands, the company faced mounting pressure on their fulfillment operations. Late-night orders, space constraints, and the need for error-free picking pushed them to seek a more efficient solution — one that could ensure operational stability even during peak periods.

The Solution: Streamlined, Automated Picking And Packaging

Zajadacz implemented an AutoStore system that integrates automated storage with precise order fulfillment. Here's how the core elements work together:

• ‍Pick and Pack integration: AutoStore Robots retrieve items and deliver them to Ports, where workers pack them directly into right-sized cartons for shipping.‍
• Automated packaging: A comprehensive packaging system handles carton sealing, labeling, and logo printing for consistent branding.‍
• Buffer storage and shipping: RelayPorts enable temporary storage of finished packages within the AutoStore system until shipping time.‍
• Seamless dispatch: The system's Robots manage the final retrieval of packages, preparing them efficiently for transport.

Key Benefits: Enhanced Speed, Space, and Accuracy

AutoStore delivered measurable improvements across operations:

• ‍Space maximization: The compact Grid design expands storage capacity while working within Zajadacz's existing warehouse footprint, removing the need to expand facilities.  ‍
• Improved accuracy: Order-related picking and streamlined Pick & Pack methods significantly improved picking accuracy.‍
• High-speed fulfillment: 52 Robots working across 10 CarouselPorts and 2 RelayPorts achieve processing speeds of 1,300 container deliveries per hour.‍
• Stable operations: Automation minimizes workload fluctuations during peak seasons.

These improvements position Zajadacz to maintain exceptional service levels while handling continued growth in order volumes.

Zajadacz unlocks new potential with AutoStore

Zajadacz's AutoStore implementation has delivered same-day shipping capabilities and opened doors to new business opportunities. "With the AutoStore system and the associated pre-zone, we are also opening up new business models," explains Zajadacz Managing Director Ralf Moormann. "We can condense our warehouse so enormously that we gain the capacity for fulfillment orders."

With their warehouse now optimized for both speed and space efficiency, Zajadacz has built a foundation for expansion that extends well beyond their traditional electrical components business.

Project Specifications

• ‍Implementation type: Brownfield (existing site)‍
• Robots: 52 AutoStore R5 Robots‍
• Workstations (Ports): 10 CarouselPort (4.0 type), 2 RelayPorts‍
• Bins: 64,000 Bins‍
• Integrated technology: Pick Robots, conveyor technology, automated packing, logo printing‍
• Implementation partner: AM Logistic Solutions