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Graco Inc., a global leader in fluid handling equipment, partnered with Designed Conveyor Systems (DCS) to outfit its new 500,000-square-foot greenfield Worldwide Distribution Center (DC) in Dayton, Minnesota with state-of-the-art, end-to-end automated systems. Completed on schedule in just 24 months, the facility went live in May 2024, and features cutting-edge automation from KNAPP, Geek+, and Brock Solutions.
Graco’s previous 227,000-square-foot distribution center was nearing capacity. Housing more than 40,000 SKUs, the leased facility faced constraints including an aging crane-based mini-load AS/RS and limited expansion options. Pick consolidation and pack-out processes had become bottlenecks, often requiring overtime.
To address growth projections and system limitations, Graco opted to build a new automated facility and selected DCS for its brand-agnostic, end-to-end approach. Take a tour of the operation via the video below.
Automated Order Fulfillment and Pick Consolidation
DCS collaborated with Graco’s operations team and automation suppliers to deliver a tailored solution. At the heart of the new system is the KNAPP OSR Shuttle Evo AS/RS, with 25 levels of shuttles and automated lifts feeding six goods-to-person picking stations.
Inventory not suited for the shuttle system is stored in pallet racks and carton flow zones with pick-to-light modules. To eliminate manual order consolidation, DCS implemented Geek+ PopPick directed by Brock Solutions’ warehouse control system (WCS). The system uses autonomous mobile robots (AMRs) to stage and deliver totes for sequencing and routing to a 12-station pack-out zone.
Pack stations are equipped with light-guided systems to highlight specific products or tote locations, boosting accuracy and ergonomics. The facility also includes 1.5 miles of motor driven roller conveyor, all coordinated by Brock’s WCS interfacing with Graco’s warehouse management system (WMS).
The Results
The project met its timeline thanks to DCS’s comprehensive project management, close coordination with contractors, and early associate training.
“DCS truly was an end-to-end automation project manager,” said Jeff Weber, Graco’s Distribution Operations Manager. “The DCS team made sure all the equipment was here on time and coordinated all of our automation vendors — all the way from commissioning, to install, to startup. They have been very helpful and supportive through this entire project.”
Thinking about implementing automation in a new or existing distribution center? Connect with DCS to learn how we can help you achieve your goals.
