Scentsy, a global leader in fragrance-based products, faced a challenge familiar to many fast-growing e-commerce businesses: scaling fulfillment without compromising speed, accuracy, or customer experience. Known for frequent product launches and seasonal collections, Scentsy needed a solution that could keep pace with demand and support long-term growth.

Through a strategic partnership with Dematic, Scentsy implemented an automated fulfillment solution with a modular design and powered by intelligent software that has transformed its operations today and will scale to transform its operations tomorrow.

Scentsy’s 160,000-square-foot order fulfillment center in Meridian, Idaho was originally designed for manual operations. As order volumes increased and SKUs expanded, the operation encountered limitations:

• Manual picking throughput capped at 300 units per hour
• Seasonal demand spikes caused bottlenecks and delayed shipments
• SKU proliferation strained available storage space
• Lack of real-time visibility delayed inventory accuracy and decision-making
• Existing infrastructure offered limited scalability

Dematic worked with Scentsy to develop and implement a high-performance, future-ready solution with three core components:

AutoStore™ empowered by Dematic

An AutoStore system handles inventory control. AutoStore is an advanced automated storage and retrieval system (AS/RS) designed for high-density, high-throughput warehouse operations. Its modular grid structure — combined with fast-moving robots — maximizes space, accelerates inventory retrieval, and adapts to changing needs. The Scentsy operation features 20,800 bins for high-density inventory storage, 100 R5 robots for fast and accurate product retrieval, and 16 carousel ports plus two conveyor ports for efficient picking and replenishment. This design maximizes space utilization and ensures rapid access to inventory.

Dematic Software

Dematic Software manages inventory movement, task allocation, and order batching in real time. By seamlessly integrating with Scentsy’s existing software systems, Dematic Software provides full visibility and control for smarter, data-driven decisions.

Pick-to-cart system

To streamline e-commerce order processing, a pick-to-cart system supports all batch picking for the operation. This reduces manual handling and accelerates throughput, especially during peak seasons.

Scentsy’s order fulfillment center evolved from a manual, capacity-limited operation into a high-performance, automated operation. The impact was immediate and measurable:

• Picking capacity increased by nearly 50%.
• Storage footprint reduced by half.
• There was no reduction in headcount as employees transitioned into new, higher value-added roles.
• Digital order access reduced paper tickets.
• AutoStore’s low-power design provided improved energy efficiency.

Scentsy now delivers faster, more accurate orders with a fulfillment model that delivers agility and long-term growth. The modular design supports future expansion and predictive analytics for continuous improvement.

From high-density storage to intelligent software orchestration, Dematic provides solutions that solve current challenges and scale to solve future challenges. Contact us to find out how we can help future-proof your operations.