In recent years, the company grew rapidly and became a major player in the Dutch market. That growth put pressure on its logistics operation. The existing warehouse in Enschede could no longer deliver the output Elektramat needed, and the previous solution was not scalable enough to grow with the business.
“The customer is number one for us, We need to serve them quickly and efficiently at all times.”
To create a logistics operation ready for the next phase of growth, Elektramat moved to a new facility in Almelo and partnered with Syncore, formerly Reesink Logistic Solutions/Lalesse Logistic Solutions, to implement a scalable AutoStore solution.
The challenge: growth beyond the existing warehouse
Elektramat’s previous logistics setup included Vertical Lift Modules, but the system had reached its limits. As online order volumes continued to rise, the company needed a fulfilment process that could support higher output, improve efficiency, and scale without holding back future growth.
“Our warehouse in Enschede could hardly deliver the output we needed. The vertical lifts were not scalable.”
Automation was a strategic decision, not just a technical upgrade. Elektramat needed a partner that could think along with the business, adapt to its process, and support future expansion.
Why Syncore
Elektramat chose Syncore because the proposed solution matched the company’s process and growth ambitions. The quality of the system design, the flexibility of the approach, and the ability to scale were decisive factors.
“Automation is not something you do lightly, you look for a partner that thinks and grows with you.”
Throughout the project, Syncore supported Elektramat with a flexible approach. The collaboration allowed questions, changes, and next steps in the optimization process to be handled quickly and practically.
The solution: compact storage, efficient picking, and built-in scalability
At the heart of the new logistics system is an AutoStore installation with:
- 70,000 storage bins
- 64 Red Line robots
- 16 multifunctional workstations
- LogiCS Warehouse Control System
- Light pointers at the workstations
- Integrated conveyor technology in collaboration with Arco Solutions
- Expansion provisions for future workstations, charging stations, and grid growth
The system is designed to deliver more than 2,000 picks per hour. It gives Elektramat compact storage, efficient goods-to-person picking, and an ergonomic process for warehouse employees.
AutoStore was selected because it uses warehouse space efficiently while remaining highly scalable. The system can grow by adding storage capacity, workstations, and robots without stopping daily operations.
Designed from the end goal backwards
Syncore designed the system around Elektramat’s desired future situation, then worked backwards to the capacity required today. This approach made it possible to create a solution that performs immediately while keeping the path to expansion open.
The current storage capacity can be expanded until the system reaches 72,000 bins. On the performance side, extra workstations can be added in the prepared expansion zones when order volumes increase. Additional robots can also be added without stopping operations.
The system is prepared for phased expansion. First, the current AutoStore can be extended toward the conveyor line. In the final intended setup, the system can be mirrored and built out on the other side, increasing capacity to approximately 150,000 bins.
LogiCS WCS: connecting the operation
The complete installation is controlled by LogiCS, Syncore’s Warehouse Control System. LogiCS connects Elektramat’s Warehouse Management System with AutoStore and coordinates inbound and outbound processes.
The software manages order processing, product information, system performance, and real-time process monitoring. At the workstations, light pointers show operators exactly which bin compartment to pick from, helping improve speed and reduce picking errors.
All workstations are multifunctional, so they can support inbound goods receiving or outbound order picking depending on operational demand.
Integrated conveyor flow
The AutoStore system is integrated with internal conveyor technology developed with Arco Solutions. The conveyors can support both empty shipping carton supply and incoming goods handling.
This creates a flexible material flow that supports the full fulfilment process, from storage and picking to downstream order handling.
Fire protection for a scalable AutoStore layout
Because the warehouse already had a roof sprinkler system, an additional fire protection solution was implemented for the AutoStore.
The system includes two remotely controlled fire monitors with directional nozzles. Infrared cameras continuously scan the AutoStore grid for elevated temperatures, while an aspiration system detects smoke particles in the air.
The fire monitors are positioned at the edge of the current AutoStore layout, allowing them to protect future expansions as well.
Results
With the new AutoStore system, Elektramat now has a scalable fulfilment platform designed for speed, accuracy, and continued growth.
Key outcomes include:
- More than 2,000 picks per hour
- Immediate improvement in error rates and processing times
- Streamlined operator workflows through LogiCS and visual pick support
- Improved inventory accuracy through sleeve registration and compartmentalization
- Compact storage in the new Almelo facility
- Expansion-ready infrastructure for future growth
- Ability to add robots without stopping operations
- Future expansion path toward approximately 150,000 bins
Ready for Continued Growth
Elektramat’s AutoStore installation gives the company the logistics foundation it needs to keep growing. By combining compact storage, efficient picking, integrated software, flexible workstations, conveyor technology, and phased expansion options, Syncore helped Elektramat create a fulfilment operation that can support today’s demand and tomorrow’s growth.
“This is what we do. We built smart, scalable logistics for companies that want to move forward. Tailored and future-proof”
