Mixed Case Fulfillment

Mixed case fulfillment – mixed case palletizing solutions

Managing high labor costs, space constraints and time limitations don’t have be ongoing burdens for companies that want to optimize their warehouses and distribution centers. 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 Fulfillment solution optimizes 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 Fulfillment 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 fulfillment?

Mixed case fulfillment 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 palletization software customizes mixed pallets to meet the specific needs and demands of all warehouses in your network. Dematic Mixed Case Fulfillment 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 fulfillment 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 palletizing station based on their predefined sequence on the shipping pallet.
  3. Cases are arranged on pallets by automatic palletizers or by operators at ergonomic palletizing stations.
  4. Pallets are wrapped as each layer completes to ensure stability.
  5. The finished pallet is labeled as required and is delivered to the shipping area.


What are the advantages of mixed case fulfillment?

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

  • Reduce Labor Dependency: Decreases warehouse operational staff by 50–70% compared to traditional manual methods.
  • Ship More in a Single Trip: Maximizes 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 minimizing human errors. 


Dematic products for automated mixed case order fulfillment 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 minimizes 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 fulfillment solutions dramatically reduce picking labor 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 maximized for efficiency, Dematic takes automation to the next level. Dematic Mixed Case Fulfillment technology starts with software that ties directly into your inventory management processes. Using algorithms to optimize order fulfillment and maintain optimal efficiency, Mixed Case Fulfillment releases your order pallets and ensures on-time delivery to your outbound dock.

It is critical to select the right supplier - one that will be a trusted partner throughout the entire process.

As a company that’s led innovation in Supply Chain for more than 200 years, Dematic provides the widest range of solutions and the expertise to build the solution you need for complete control and visibility over your operation.

Our solutions are tailored to your business challenges. Using standardized sub-systems and industry-leading insight and expertise, Dematic provides world-class integrated hardware, software, and support to help you empower people, optimize space, drive growth and improve efficiency.

With Dematic, you can grow your business to compete locally, retain customer loyalty, and deliver with speed and accuracy on a global scale.

Related insights

Let's get started

Tell us about your needs and our experts will guide you down the right path.

Complete the form or give us a call: