Mixed Case Fulfilment

Mixed Case Fulfilment – Mixed Case Palletising Solutions

Managing high labour costs, space constraints and time limitations don’t have be ongoing burdens for companies that want to optimise their warehouses and distribution centres. For mixed pallet loads, ensuring high performance and compact transportation can be difficult without a system to address and mitigate unforeseen circumstances. 

The Dematic Mixed Case Fulfilment solution optimises warehouse space with a cube layout that makes use of vertical space. The solution reduces transportation costs with optimally sized pallet loads and decreases the need for warehouse operational staff.

The Dematic Mixed Case Fulfilment solution also improves retail replenishment by building aisle-ready pallets that simplify restocking. The automation provides significant throughput increases and prepares your operations for unforeseen disruptions.

What is mixed case fulfilment?

Mixed case fulfilment helps companies operate more cost effectively and competitively by building mixed case pallets designed for aisle-readiness and compact transportation. The solution includes software that works for you — technology that operates in three environment zones, including ambient, chilled, and frozen. 

With its scalable design, the solution can handle future expansion and increases in throughput demand. Dematic software manages equipment and workflow processes while our palletisation software customises mixed pallets to meet the specific needs and demands of all warehouses in your network. Dematic Mixed Case Fulfilment is best suited in retail operations that include grocery, general merchandise, or food and beverage.

The software maintains the stability of a loaded pallet regardless of stack height, weight distribution, or pallet pattern. It provides easy access to operational intelligence with role-based screens and uses data-driven decision making and validation based on lean principles.

How does automated mixed case order fulfilment work?

  1. Product is stored in a high-density case/tote buffer system (Dematic Multishuttle®, Mini-Load AS/RS, or AutoStore).
  2. Cases/totes are retrieved and automatically transported to the manual or automatic palletising station based on their predefined sequence on the shipping pallet.
  3. Cases are arranged on pallets by automatic palletisers or by operators at ergonomic palletising stations.
  4. Pallets are wrapped as each layer completes to ensure stability.
  5. The finished pallet is labelled as required and is delivered to the shipping area.

 

What are the advantages of mixed case fulfilment?

Mixed case pallets are designed for aisle-readiness and compact transportation. Advantages:

  • Reduce Labour Dependency: Decreases warehouse operational staff by 50–70% compared to traditional manual methods.
  • Ship More in a Single Trip: Maximises the space available in a trailer, reducing transportation costs by up to 18%.
  • Work in Three Environment Zones: Provides a range of temperature zones: ambient, chilled, and frozen.
  • Increase Client Satisfaction: Decreases product damage, inaccurate orders, and stockouts by minimising human errors. 

 

Dematic products for automated mixed case order fulfilment solutions

Integrated package conveyor technology is designed to provide flexible solutions

Benefits of case and tote conveyor

Durable design extends equipment life: Dematic case and tote conveyors installed decades ago are still running 24/7 today. The modular and scalable design simplifies configuration changes or system expansion.

Easy maintenance minimises downtime: Top-down access creates stress-free maintenance and repairs.

Compact system reduces footprint: Dematic accumulating incline and decline conveyors combine functionalities to reduce the amount of required floor space.

 

Reduced product damage improves customer satisfaction: Dematic accumulation and gapping systems handle loads gently with minimal contact between items to reduce product damage.

Minimal energy consumption is good for the environment and saves money: Multiple drive options and our advanced technology ensure the most efficient use of energy. Dematic experienced conveyor experts can right-size your system for optimal efficiency.

Dematic automated mixed case order fulfilment solutions dramatically reduce picking labour and rapidly build high-density, store-ready pallets and carts.

With custom software developed by 800 different in-house experts who ensure that your system is maximised for efficiency, Dematic takes automation to the next level. Dematic Mixed Case Fulfilment technology starts with software that ties directly into your inventory management processes. Using algorithms to optimise order fulfilment and maintain optimal efficiency, Mixed Case Fulfilment releases your order pallets and ensures on-time delivery to your outbound dock.

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