AutoStore Expands Operations in LT Apparel Group’s Distribution Center

LT Apparel Group, a New York-based, family-owned company founded in 1958, is known for designing, manufacturing, and distributing high-quality children's clothing. To support ambitious goals for business growth, they needed to smooth out their distribution processes while bringing previously outsourced Third-Party Logistics (3PL) operations in-house.

The company had already seen the benefits of implementing an AutoStore system and knew that expanding it would improve their product and order flow while building capacity at their warehouse. Empowered by KPI Solutions, LT Apparel enlarged their existing AutoStore system at their Browns Summit, North Carolina distribution center.

The Challenge: Meeting Aggressive Growth Goals

LT Apparel faced several operational challenges when it came to meeting their ambitious goal of processing 150,000 units per day during peak season. This meant that they needed to accommodate 10,000 additional SKUs within their existing facility footprint and simplify their distribution methods. They also wanted to bring previously outsourced 3PL volume in-house to save on costs.

The company’s North Carolina distribution center required immediate improvements and a long-term strategy to improve product and order flow and reduce labor dependency.

The Solution: Integrated Automated Storage System

After making significant investments in automation technology in recent years, LT Apparel chose a solution that blended two robotic technologies, centred around the expansion of their existing AutoStore AS/RS system.

The AutoStore system was expanded to include 38,000+ Bins, 36 red line Robots, 9 ConveyorPorts, and 5 VAS conveyor pick/replenishment Ports. This was integrated with a tSort system featuring 400+ destinations with 125 Robots, 5 AutoStore induct stations, and 4 manual induct stations.

This provided expanded capacity in a smaller footprint with flexible storage for a rotating assortment of SKUs.

Key Benefits: Peak Performance with Fewer Resources

AutoStore's technology provided LT Apparel with the operational improvements needed to support their growth. The system delivered both immediate efficiency gains and long-term scalability advantages.

• Increased storage capacity: The system provided additional storage capacity within the existing facility footprint.
• Faster order fulfilment: Improved processes were seen throughout the facility, which led to faster, more efficient order fulfilment.
• Increased order throughput: Increased order throughput enabled order volume growth and enabled LT Apparel to meet peak demand.
• Time and cost savings: AutoStore provided the capacity to bring previously outsourced 3PL volume in-house, resulting in time and cost savings.

AutoStore solved LT Apparel's immediate capacity challenges and created a foundation for sustainable long-term growth.

Building a Profitable Future on Strong Foundations

LT Apparel is on a fast track to achieving and exceeding their goals. The AutoStore system can easily be expanded with additional Robots, Grid extensions, and Workstations without operational disruption. LT Apparel now has the ability to scale quickly and efficiently, positioning the company for continued business growth.

Project Specifications

• Installation type: Brownfield
• Robots: 36 AutoStore red line Robots
• Workstations (Ports): 9 AutoStore ConveyorPorts; 5 VAS conveyor pick/replenishment ports; 5 AutoStore induct stations; 4 manual induct stations
• Bins: 38,000+ Bins
• Integrated technology: Tompkins Robotics tSort system
• Implementation partner: KPI Solutions