Frisco quadruples order fulfillment speed with automation

Frisco faced rising demand for its same-day grocery services. To meet customer expectations and sustain growth, it became clear that their previous fulfillment approach could no longer keep pace.

Frisco’s traditional fulfillment system highlighted several operational challenges that had to be addressed for sustained growth and customer satisfaction. These challenges included:

• Capacity constraints: Expanding order volumes strained their systems, limiting daily fulfillment capabilities,
• Labor dependency: Manual processes increased operating costs and created exposure to workforce fluctuations,
• Perishable waste: Lagging handling times led to increased spoilage, further impacting profitability,
• Scalability roadblocks: Their existing system lacked the adaptability needed to accommodate future expansion.
   

Frisco’s new 11,000m² facility was outfitted with TGW’s state-of-the-art shuttle warehouse systems, offering 36,000 storage locations. Key features included:

• Advanced storage system: Products are stored in EUROTEC containers supplied by Utz. These containers are designed for use in the automated warehouse, where goods are efficiently stored on shelves. When products are required, the containers are retrieved by a high-speed shuttle system and delivered to ergonomic completion stations. At these stations, human workers select the correct products and quantities, packaging them into bags for customer orders.
• High-speed throughput: The shuttle systems handled over 4,000 items per hour, ensuring rapid alignment with Frisco’s growing fulfillment demands.

Functional highlights of the nestable tote

• Guides for dividers to separate into up to 3 compartments per box.
• Slots for fixing up to 3 bags in one box.
• 4 handle slots for ergonomic handling.
• Perforated sidewalls for ensuring rapid airflow and ventilation.
• Identification features for streamlined inventory management and tracking.
• Water drainage holes for ensuring compliance with fire protection rules.
• Stacking direction indicator for proper stack and nest positioning.
• Safety tab for secure stacking.