eXXpozed Achieves 87% Reduction in Warehouse Footprint with AutoStore

High-quality outdoor and extreme sports equipment retailer eXXpozed faced significant scalability challenges as it expanded its product range and international presence. AutoStore, empowered by Element Logic, provided the solution with a warehouse system that dramatically reduced space requirements and boosted efficiency.

The Autostore system ensures that eXXpozed can offer a wide and deep product range in the store, and efficiently manage both e-commerce and in-store operations under one roof.

The project was significant due to its compact size and unique location. The AutoStore system at eXXpozed is integrated one floor below their retail store, showcasing the versatility and adaptability of our solution.

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The Challenge: Traditional Warehousing Can’t Keep Up

As eXXpozed's popularity surged, its traditional warehousing methods struggled to keep pace with demand:

• Manual, labor-intensive processes hindered efficiency.
• Existing warehouse space lacked the adaptability needed for rapid growth and scalability.
• The need to seamlessly handle various order types — direct-to-consumer, e-commerce, and in-store pickup — added complexity to operations.
• Customers expected seamless efficiency and service across all channels.

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The Solution: Compact Efficiency for e-Commerce and In-store Operations Under One Roof

The AutoStore system at eXXpozed consists of 10,950 storage Bins, stacked 16 high in a Grid structure. The system's compact design allowed for integration directly below eXXpozed's retail store, occupying just 450 m² (4,844 ft²). For comparison, a manual warehouse would need around 3,500 m² (37.674 ft²) to store the same quantity of goods.

The system also creates a unique visual experience for customers, who can see the AutoStore Robots through a window from outside the building. Bindhammer explains that they now “offer our customers a world of sports and outdoor, in which they can experience our products with all their senses”.

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Twelve AutoStore Robots move on top of this aluminum grid, using their gripping units to lift and deliver Bins to the picking Ports. Each Robot has four wheels, allowing movement in any direction at speeds up to 3.1 meters (10.2 feet) per second. A central software system controls the Robots' movements and tracks each Bin's location. The Robots communicate with the main controller via WLAN, receiving instructions for Bin retrieval and delivery to picking stations. Robots automatically return to charging stations located around the Grid's edge when not in use or when batteries are low. Workstations handle both incoming and outgoing goods, adapting to different process requirements as needed.

This system replaces traditional warehouse layouts of large storage rooms and long walkways. Instead, eXXpozed now has compact workstations where goods are delivered directly to pickers. Staff process both online orders and in-store pickup requests from these stations, increasing output while reducing physical effort.

Key Benefits: Dramatic Space Saving

AutoStore has turned eXXpozed's warehouse into a highly efficient, adaptable space, maximizing its use without the need for costly expansion.

• Space efficiency: The system requires only 450 m² (4,844 ft²), compared to the 3.500 m² (37,674 ft²) that equivalent traditional warehousing would need — an 87% reduction.
• Increased picking speed: The picking speed has increased to 370 picks per hour at peak times.
• Improved customer satisfaction: Faster processing times for online and in-store orders improves the customer experience.
• Enhanced retail experience: The unique placement of the AutoStore system adds a visual element to the retail store.

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eXXpozed Increases Customer Satisfaction

eXXpozed has overcome its immediate challenges and positioned itself for continued success in the competitive sportswear and outdoor equipment market. The company can now meet and exceed customer expectations while maintaining the agility to adapt to future market demands. With significantly reduced space requirements, increased picking speed, and growth potential secured, eXXpozed's operational efficiency is at its peak.

As eXXpozed continues to grow, AutoStore provides a solid foundation for ongoing success, according to Bindhammer: "In every respect, AutoStore and the collaboration with Element Logic have contributed to increasing customer satisfaction and further expanding our market position. For us, AutoStore was the best decision so far in terms of efficient and resource-optimized warehouse management. The fully automated warehouse fits perfectly into our existing infrastructure of our mail order software and thus guarantees us future security and sustainable growth opportunities."

Project Specifications

• Implementation type: Brownfield (existing site)
• Robots: 12 Robots
• Workstations (Ports): 3 CarouselPorts; 1 ConveyorPort
• Bins: 10,950 Bins
• Integration partner: Element Logic