Upscaling Online Fashion Sales with AutoStore

Facing rising demand for their Seventyseven urban streetwear line and rapidly diminishing space, Styleboom needed an innovative, space-saving automated warehouse solution to maintain their market position. AutoStore stepped in to provide the system they needed.

Germany-based fashion company Styleboom sells clothing online under their Seventyseven brand. In 2020, the company’s success prompted them to move to a new warehouse and overhaul logistics to increase throughput, capacity, and efficiency.

The challenge

The new facility was planned across three segments, with Styleboom initially expecting to require 4,500 m² (48,400 ft²) of shelving space.

In their previous facility, orders were picked manually in a multi-level shelving system based on article numbers. This resulted in high stress levels, inefficient workflows, and a high error rate.

It became clear that an automated solution was needed. AutoStore provided an automated warehouse system designed for maximum efficiency.

Source: Element Logic

Benefits of the AutoStore system

Given the space requirements, an automated solution was the only viable option. AutoStore offered key advantages, including a modular system design based on vertically stacked Bins beneath a rail system, where Robots enable fast retrieval and delivery.

Styleboom reduced required storage space from 4,500 m² to just 1,300 m² — less than 30% of the original estimate. Processing times improved significantly, allowing faster and more accurate picking and packing.

“Within three seconds, a new Bin is presented at the Port. The system knows exactly where each Bin is, calculates optimal paths, and coordinates the Robots efficiently.”

Tomasz Stefanowski
Operations Manager, Styleboom

Additionally, the warehouse management system (WMS) simplifies onboarding, allowing new employees to be trained in under 30 minutes.

How the system works

The AutoStore system is built around a modular Grid of aluminum rails. Robots travel across the grid to retrieve Bins from vertical stacks and deliver them to Ports.

This vertical storage model enables significant space savings while remaining highly adaptable to facilities of different sizes and layouts.

The initial system included 52 Robots, 7 Ports, and 52,000 Bins across 16 levels. After expansion, the system now includes 74 Robots and 9 Ports.

“With the system, 14 employees can handle the same picking volume as 80–90 employees previously. We process 6,000 orders daily with zero errors.”

Tomasz Stefanowski
Operations Manager, Styleboom

Robots deliver Bins to different workstation types: Carousel Ports, Relay Ports, and Conveyor Ports.

Source: Element Logic

An efficient returns process with AutoStore

After implementing AutoStore, Styleboom significantly improved its returns handling process:

1. Returns are inspected
2. Items are sorted onto a trolley
3. Trolley is brought to an AutoStore Port
4. Task group is assigned to the Port
5. Operator switches from picking to returns
6. Items are returned to the correct Bins by SKU
7. Trolley is emptied and process completed
8. Operator switches back to picking

Source: Element Logic

Returns are placed on a trolley and reintroduced into the correct SKU locations. Robots then transport the Bins back into the storage Grid.

The completed solution exceeded expectations, delivering improved quality, efficiency, capacity, and scalability for future growth.

Project specifications

• Installation type: Greenfield (new site)
• Robots: 74
• Ports: 9 Carousel Ports
• Bins: 52,000
• Partner: Element Logic