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- References
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Executive summary
KNAPP UK partnered with Utz UK to create an innovative storage and transportation solution for The Very Group’s automated fulfillment center, Skygate. By Integrating Utz's Evo Stacknest tote system into KNAPP’s shuttle technology, the project increased storage capacity and streamlined operations for 6 million inventory items. This solution helped consolidate multiple sites into a single highly automated center, reduced operational complexity and improved order fulfillment efficiency.
The client
KNAPP UK are an industry leading manufacturer of intelligent warehouse systems using the latest solutions in digitalization, software, automation, and robotics. Knapp specializes in industries such as E-Commerce, Retail, Fashion, Pharmaceuticals, and Grocery. Their client, The Very Group, is a prominent UK-based digital retailer, with a focus on providing efficient and sustainable fulfillment services for its online shoppers.
Utz - KNAPP – Very Group | East Midlands, United Kingdom
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The challenge
The Very Group required a highly efficient and scalable solution for their new Skygate automated fulfilment center. The main challenge was to consolidate several sites into a single facility while handling a diverse inventory of boxed and hanging goods, totaling 6 million items. Additionally, the solution needed to incorporate eco-friendly practices, maximize storage capacity, and seamlessly integrate with KNAPP’s OSR Shuttle™ Evo and pocket sortation systems.
The Solution
KNAPP and Utz collaborated closely to create the Evo Stacknest tote solution, a versatile and space-saving storage container designed to meet the specific needs of The Very Group. The tote solution was optimized for use with KNAPP’s shuttle system, allowing for efficient picking, packing, and return processes. Made from recycled materials, the containers aligned with The Very Group’s sustainability goals.
Utz provided over 500,000 Evo Stacknest containers, each 650 × 450 × 330 mm, which fit seamlessly into KNAPP’s automated systems. The totes were relabeled and integrated with advanced scanning technology to ensure error-free induction into the system. Utz's on-site engineering support helped overcome mid-project challenges, such as adjustments to labeling requirements.
Implementation process
- Initial Consultation: KNAPP and Utz assessed the system requirements and sustainability objectives of The Very Group.
- Prototype Development: Utz designed prototypes of the Evo Stacknest totes, which were tested within KNAPP’s OSR Shuttle™ Evo system.
- Phased Rollout: After the testing phase, the solution was rolled out in phases to ensure smooth integration without disrupting ongoing operations.
- On-Site Support: Utz provided continuous engineering support to address challenges like mid-project design changes and system labeling.
Results
The collaboration between KNAPP and Utz led to significant operational improvements at The Very Group’s Skygate facility:
- 25% increase in storage efficiency: By utilizing the space-saving design of the Evo Stacknest containers, the facility maximized storage capacity for its 6 million inventory items.
- Error-free scanning and induction: The totes were optimized for seamless integration with the automated scanning system, ensuring 100% accuracy in order processing.
- Sustainability gains: Utz’s containers, made from recycled materials, helped The Very Group meet its sustainability targets.
The solution more than fitted the brief, offering a great storage solution that was exclusively developed for our Evo shuttle system. The strong partnership with Utz ensured that some challenges seen mid-project, when there were design changes to the labelling requirements, were overcome with the help of on-site engineering support.
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