DTC fulfillment bagger line — 1,800 orders/hr at 99.7% accuracy
Pick-to-bag fulfillment cell with vision-verified SKU match, auto-bagger, and print-and-apply at sustained 1,800 oph.
- Client
- Confidential — DTC Apparel Brand
- Location
- Indiana, USA
- Capabilities
- Turnkey Line Build · Machine Vision · Service & Support
The challenge
DTC apparel brand grew 4× year over year and outsourced fulfillment was missing peak-season SLAs. They wanted in-house control without doubling pickers.
What we built
Pick-to-light front end, vision SKU verification with Cognex DataMan, Sharp Max auto-bagger with integrated print-and-apply, and a 4-lane diverter into outbound chutes. Aligned to their Shopify-fed OMS via REST.
Key equipment
- Sharp Max auto-bagger
- Cognex DataMan 380
- Lightning Pick PTL
- Honeywell Genesis scanners
From the floor
Illustrative image — representative of project scope; customer-identifying details have been removed.
Results
Throughput hit 1,800 orders per hour with 58% less labor than the outsourced baseline. Accuracy ran 99.7% across the first two peak seasons.
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