Matalan is further expanding its distribution centre in Knowsley near Liverpool with automation technologies from Knapp. The British fashion and homeware retailer has been relying on scalable solutions from the Austrian intralogistics specialist since 2021.
The next expansion stage of the omnichannel fulfilment hub is scheduled to become operational in 2027. The facility will then comprise a total of eight Evo Shuttle 1D rack line shuttle systems and the same number of pocket induct stations, 16 picking and decanting workstations as well as five dispatch ramps.
Gradual automation of the logistics centre began in 2021 with a single PocketEngine pocket sorter, which transports and buffers hanging as well as flat goods – such as shirts, shoes, and accessories – together. By planning in modules, the company wanted to provide space to explore workflows, optimise processes and react flexibly to market requirements.
Picking accuracy increased to 99.8 percent
Based on positive experiences with the system, Matalan expanded the facility in 2024 with a second pocket sorter, accompanied by an Evo Shuttle 1D with a capacity of 100,000 containers, six decanting workstations, and two spiral conveyors. In addition, the company installed Knapp’s intelligent logistics software KiSoft and deployed a customer service team from the manufacturer on site.
Thanks to these expansions, the retailer was able to increase order picking accuracy to 99.8 percent and extend its order cut-off time for next-day deliveries by six hours. To record article master data more efficiently, Matalan integrated the MultiScan digital volume measuring device in the same year. This automatically captures all morphological information, such as item number, dimensions, weight and quantities, in a single step.
Shared inventory supplies stores and online business
Most recently, the company modernised store fulfilment this year. Ergonomically designed goods-to-person workstations have now replaced manual picking.
Today, the distribution centre is capable of one-touch omnichannel distribution from a single pool of stock, processing up to 100,000 online orders a day. Matalan has implemented all previous expansions during ongoing operations. This is also planned for future expansion steps.
