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Parcel Handling
Package Handling
DCS’s design and engineering team has more than 40 years of experience creating unique parcel handling systems for diverse customer applications. With installations including semi-automated handling in small city distribution centers and fully automated, integrated hubs with advanced conveyor and sorter equipment, DCS routinely thinks outside the box.
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E-Commerce Multi Channel Fullfillment
E-Commerce and Multi-Channel Fulfillment
DCS designs and implements end-to-end warehouse automation solutions for e-commerce and multi-channel retailers that address numerous workflow challenges. This includes solutions for receiving, putaway, storage, replenishment, order fulfillment, picking, packing, sortation, and outbound shipping. Our custom integrated warehouse, distribution, and fulfillment systems draw from a deep pool of conventional, semi-automated, and automated material handling technologies.
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Various Distribution Applications
Whether an operation is considering the construction of a new distribution or fulfillment center, or a retrofit or expansion of an existing facility, it’s important to create a solution that fits the overarching supply chain strategy. DCS has four decades of experience designing and integrating comprehensive, end-to-end material handling solutions that meet a multitude of operational goals. Whether conventional, semi-automated, or fully automated, DCS can help your organization implement a custom solution that meets its goals while maximizing return on investment (ROI).
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Supply Chain Consulting
The DCS Supply Chain Consulting team offers a range of services to help your operations address the challenges it faces. Working in partnership with you, DCS consultants analyze your business data- existing workforce, workflow processes, inventory, order data, operations, and more- to determine a strategy that addresses your unique needs. Whether you need an operations assessment, process improvement recommendations, or distribution design services, DCS consultants will help guide you to the material handling system or operational solution that best meets your current and future needs, as well as your budget.
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Distribution Center Design Consulting
DCS provides distribution center design and warehouse design consulting for new facilities, expansions, and existing warehouse retrofits. Using operational data, the DCS consulting team develops facility layouts, processes, material handling strategies, and automation concepts based on the unique requirements of each operation.
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Warehouse Automation Consulting
DCS provides warehouse automation consulting to help distribution and fulfillment operations determine where automation makes sense, what level of automation is appropriate, and how potential solutions align with operational and financial goals.
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Operations Assessment & Optimization Consulting
DCS provides warehouse and distribution center operations with assessment and optimization consulting to help identify inefficiencies, improve productivity, and develop a clear path toward better performance.
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Supply Chain Strategy & Optimization Consulting
DCS provides supply chain strategy and optimization consulting to help organizations define how their distribution operations should evolve to support broader business goals.
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Warehouse Technology & Software Consulting
DCS provides warehouse technology and software consulting to help organizations assess existing systems, define requirements, and develop a technology strategy aligned with their operational needs and future goals.
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Supply Chain Network Design & Optimization Consulting
DCS provides supply chain network design and optimization consulting to help organizations determine how facilities, inventory, transportation, and fulfillment should work together across their distribution network.
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Customer Support
Customer Support
Keeping your warehouse operations and material handling systems running smoothly and at the peak of productivity are the goals of DCS’ Customer Service Team. By partnering with DCS, your warehouse automation solution is supported from commissioning to end of life. You’ll receive comprehensive in-house training of your personnel, including specialized training of your designated internal system expert. Plus, DCS offers a complete package of spare parts and expert system troubleshooting support from qualified engineers dedicated to your installation.
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System Design and Integration
System Design & Integration
DCS offers a broad range of material handling equipment and automated system design, installation, and integration services for a multitude of projects. These include retrofits, expansions, upgrades, and more. While every project is unique, our system design and execution processes are the same, encompassing meticulous attention to detail, frequent communication, and a dedicated partnership with our clients.
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Lifecycle Services
Stop reactive repairs. Lifecycle Services provides expert preventive maintenance and 24/7 technical support to protect your automation and MHE availability.
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Retail Distribution
Designed Conveyor Systems (DCS) engineers retail distribution center automation, warehouse execution software and material handling systems that keep stores stocked and orders moving through every channel and season.
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Pet Care
Pet food distribution operations are anything but standard. From bulky kibble bags to delicate fish tanks, stock keeping unit (SKU) complexity and fulfillment pressure are always on the rise. Designed Conveyor Systems (DCS) partners with leading pet retailers to design and engineer automation, software, and material handling systems that keep operations agile, accurate, and ready for what’s next.
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Home Improvement
When your distribution center handles everything from hammers to hot tubs, operational complexity isn’t a challenge—it’s your daily reality. Home improvement retailers face intense pressure to meet rising consumer expectations across multiple channels—from in-store pickups to last-mile delivery. At Designed Conveyor Systems (DCS), we specialize in engineering material handling and automation solutions that help home improvement distribution centers keep pace, reduce cost, and drive accuracy at scale.
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Sporting Goods
Navigating the unique demands of the sporting goods retail industry requires a distribution strategy that’s both agile and precise. From handling seasonal surges to managing a diverse range of products—from bulky equipment to small accessories—your warehouse operations are the key to a seamless customer experience. Our expertise helps sporting goods retailers streamline their distribution warehouses, improving order accuracy, boosting productivity, and ensuring your team can efficiently move products from the receiving dock to the final customer, no matter the season.
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Shoe Aisle
Footwear
In the fast-paced world of footwear retail requires a distribution strategy that can handle a vast array of styles, sizes, and seasonal trends with precision and speed. From managing a high volume of SKUs to ensuring accurate order fulfillment and returns processing, your distribution center is the engine that drives customer satisfaction and brand loyalty. Our expertise helps footwear retailers streamline their distribution centers, improving inventory management, accelerating order processing, and ensuring your team can efficiently move products from the receiving dock to the final customer, no matter the season.
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Life Science & Healthcare
Pharmaceutical, healthcare, and life science companies face mounting pressure from evolving regulatory requirements, rising fulfillment costs, and intensifying accuracy demands. In this environment, automation isn’t optional—it’s essential. Designed Conveyor Systems (DCS) helps distributors of these critical products stay compliant and competitive.
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Wholesale & Industrial Distribution
Designed Conveyor Systems (DCS) partners with wholesale, industrial, and electronics distributors to design efficient, optimized fulfillment solutions. Every operation DCS designs streamlines end-to-end functional processes—from inbound receiving and putaway to picking, packing, and shipping. Designed Conveyor Systems (DCS) partners with wholesale, industrial, and electronics distributors to design efficient, optimized fulfillment solutions. Every operation DCS designs streamlines end-to-end functional processes—from inbound receiving and putaway to picking, packing, and shipping.
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News Releases and Blogs
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On Time In Full Podcasts
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Case Studies
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About Us
Designed Conveyor Systems (DCS) has 40 years of experience serving major clients in multiple industries by providing material handling, full-scale warehouse operations, and conveyor design solutions that are custom crafted for their needs. DCS does not sell ready-made conveyor systems but builds relationships that empower collaboration to craft custom warehouse designs together. DCS utilizes consulting, engineering design, project management, installation services, and client support to ensure our customers can keep their promises to deliver on time.
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Projects
With more than 40 years of experience providing automated system design, installation, and integration services, DCS has created solutions for companies throughout the United States in a broad range of industries and markets. We’ve completed more than 1500 projects ranging from greenfield facilities with completely new systems to expansions and retrofits of existing operations.
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Upcoming Events
Upcoming Events
Designed Conveyor Systems values building strong relationships with our clients. Join us at our upcoming events to collaborate and discover how we can design a custom warehouse solution tailored to your unique needs.
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Distribution Center Design Consulting

Design a Distribution Center Built Around Your Operation

DCS provides distribution center design and warehouse design consulting for new facilities, expansions, and existing warehouse retrofits. Using operational data, the DCS consulting team develops facility layouts, processes, material handling strategies, and automation concepts based on the unique requirements of each operation.

Whether you’re planning a new distribution center or thinking of retrofitting an existing facility, DCS consultants bring together the right mix of space, people, processes, technology, and automation. Let DCS support your operation today and prepare you for what’s next.

Talk to a Distribution Center Design Consultant
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— What Is Distribution Center Design?

Distribution center design is the process of determining how space, inventory, people, processes, equipment, and technology should work together within a distribution operation.

An effective design considers more than the physical layout of a warehouse. It can include material flow, storage strategy, labor requirements, inventory characteristics, material handling equipment, automation, technology, throughput requirements, and future growth.

DCS takes a data-driven approach to these decisions, helping you evaluate your options and developing a practical design based on both your operational and business requirements.

Distribution Center Design Services

No two operations have the same requirements. DCS’ consultants analyze your data, processes, inventory, workflows, labor requirements, growth projections, and service expectations to develop and evaluate design alternatives specific to your business.

Our distribution center design services can include:

  • New, greenfield distribution center design
  • Existing warehouse expansions and retrofits
  • Facility layout and space optimization
  • Material flow and process design
  • Storage and inventory strategy
  • Material handling equipment analysis
  • Warehouse automation strategy and evaluation
  • Labor and staffing considerations
  • Warehouse technology and systems evaluation
  • Concept development and alternative evaluation
  • Simulation and design validation
  • Project planning and implementation support
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— Start with the Operation, Not the Equipment

The best distribution center design isn’t defined by how much automation it contains. It’s defined by how effectively it supports your operation.

DCS’ consultants start by understanding your operational data, challenges, and future requirements before determining the right solution. The consulting team evaluates conventional, semi-automated, and automated approaches based on multiple factors. These include throughput, inventory profile, labor availability, space constraints, capital requirements, service levels, and projected growth.

The result is a distribution center design built around your business—not around a predetermined technology.

New Distribution Center Design
Existing Warehouse Design & Retrofit
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New Distribution Center Design

Planning a new distribution center is an opportunity to rethink how products, people, information, and equipment move through your operation. DCS helps translate current and future business requirements into a practical facility design. From determining space and capacity requirements to evaluating layouts, workflows, storage strategies, material handling systems, and automation, DCS' consultants help establish a scalable foundation for long-term performance and growth.

System Design and Integration
Existing Warehouse Design & Retrofit

You don’t always need a new building to create a better operation. If an existing distribution center is approaching capacity, experiencing bottlenecks, or struggling to support changing requirements, DCS can identify opportunities to improve the facility you already have. DCS' consultants evaluate layout, space utilization, processes, inventory, labor, material flow, technology, and existing equipment. They then use this data to identify ways to improve capacity and performance while making better use of your current footprint.

Independent, Data-Driven Recommendations

Distribution center design decisions can have long-term operational and financial implications. DCS' consultants use operational data and analysis to help determine:

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How much space and capacity your operation requires
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How inventory should flow through the facility
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Where processes can be improved
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Which processes should remain manual and where automation may add value
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What storage and material handling strategies fit your product mix
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How labor requirements may change under different designs
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How the operation can accommodate future growth
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Which alternatives provide the strongest operational and financial case

— Distribution Center Design in Action

Building a Scalable Distribution Center for Bermuda Hospitals Board

DCS worked with Bermuda Hospitals Board to evaluate its distribution network and develop a centralized, scalable distribution center designed around its operational needs.

The engagement combined network analysis and distribution center design to help BHB develop a strategy for its current operation and future requirements.

Read the Bermuda Hospitals Board Case Study

From Distribution Center Strategy to Execution

A strong design is only valuable if it can be successfully implemented.

DCS combines supply chain consulting expertise with more than four decades of material handling systems design and integration experience. When a client chooses to move forward after the consulting engagement, DCS can support the next phases through engineering, project management, software, installation, commissioning, and ongoing lifecycle support.

This allows you to begin with an operationally driven consulting process and, when it makes sense for your business, to continue with a team that already understands the strategy behind the design.

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Distribution Center Design Consulting FAQs

Organizations often engage a distribution center design consultant when planning a new facility, relocating, expanding an existing operation, adding another location to a distribution network, approaching capacity, or considering a significant change in material handling or automation strategy.

Yes. DCS works with both new and existing facilities. For an existing distribution center, consultants can evaluate layout, space utilization, processes, inventory, labor, material flow, technology and equipment to identify opportunities to improve capacity, efficiency, and performance.

The right level of automation depends on the operation. DCS’ consultants evaluate factors such as throughput requirements, product and inventory characteristics, labor availability, space constraints, capital requirements, projected growth, and return on investment (ROI) when comparing conventional, semi-automated, and automated approaches.

The terms are often used interchangeably to mean the same thing. However, distribution center design may encompass a broader view of the operation, including inventory flow, order fulfillment, processes, labor, technology, material handling systems, and how the facility fits within the overall distribution network.

Yes. The DCS consulting team can develop and compare alternative layouts, processes, technologies, and automation concepts to help determine which approach best supports your operational and business requirements.

Yes. When a client wants to move from strategy into execution, DCS can provide engineering, system design and integration, project management, software, installation, commissioning, and ongoing lifecycle support.

Build Your Next Distribution Center with Confidence

Whether you’re designing a new distribution center, expanding an existing operation, or determining how to get more from your current facility, DCS can help turn operational data and business requirements into a practical, scalable design.