How AutoStore Powers Fast, Same-Day Pickup at Scale

Codale Electric Supply, a regional subsidiary of global B2B electrical distributor Sonepar USA, has transformed fulfillment operations in Las Vegas with an AutoStore system designed for speed, density, and long-term scalability, empowered by Kardex.

Operating in a dense urban market with exceptionally high walk-in demand from electrical contractors, Codale needed a fulfillment solution that could consolidate multiple operations, respond faster than ever, and scale with future growth within a limited physical footprint. AutoStore provided the foundation for a high-performance central distribution center that now serves as a blueprint for future Sonepar facilities across the United States.

As part of the wider Sonepar network, Codale builds on a proven automation strategy. Sonepar has deployed more than 12 AutoStore systems globally, using a standardized approach to support high-density storage, fast fulfillment, and scalable operations across its distribution network.

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The Challenge

Fragmented operations under growing demand

Following Codale’s acquisition of NEDCO in 2023, three Sonepar regional brands Codale, QED, and NEDCO were operating independently across multiple Las Vegas locations. Each site relied on manual workflows, separate ERP environments, and localized inventory visibility.

As order volumes increased, this fragmentation limited throughput and accuracy, particularly for same-day Will Call orders that are essential to electrical contractors in the Las Vegas market.

Why the challenge was significant

• High daily walk-in demand required extremely fast fulfillment
• Limited space near the Las Vegas Strip restricted expansion options
• Manual picking created bottlenecks and increased error rates
• Bulk replenishment and Will Call (same-day) orders required parallel workflows
• Sustainability goals demanded reduced packaging waste and freight emissions

Codale needed a unified, automated fulfillment model that could support both present requirements and future growth.

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The Solution

AutoStore as the foundation for unified fulfillment

Codale selected AutoStore as the core of its new Las Vegas Central Distribution Center, with the system empowered by Kardex software and integration expertise.

AutoStore provides a Goods-to-Person model that stores Bins (totes) in a compact Grid and uses Robots to retrieve inventory and deliver it directly to Ports (Workstations). This eliminates travel time, manual searching, and forklift movement, which is critical in a space-constrained urban facility.

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One platform for every order type

The AutoStore system supports two distinct workflows within the same Grid:

• Regional bulk replenishment across the Southwest U.S.
• Same-day Will Call orders for local contractors

Orders are dynamically prioritized so both workflows operate simultaneously without congestion.

How the System Works

High-density storage in minimal space

AutoStore compresses approximately 9,700 SKUs into a Grid footprint of just 5,500 ft² (511 m²), reducing floor space requirements by roughly 80% compared to traditional warehousing. This density allowed Codale to locate its Central Distribution Center, (CDC) close to the Las Vegas Strip, improving convenience for walk-in customers.

Robots, Bins, Ports, and people working together

AutoStore Robots travel on top of the Grid, retrieving Bins and delivering them to ergonomic Ports operated by warehouse employees. Every SKU is immediately accessible, enabling consistent performance even during peak demand periods.

Accuracy through guided picking

Operators are guided through each task with visual instructions at the Ports. Reduced scanning steps and clearer guidance have driven a 90% reduction in barcode scan errors, significantly improving accuracy.

The Benefits of the AutoStore System

Performance gains for customers and operations

• Will Call (same-day) orders processed 20% faster
• Standard order throughput increased by 12%
• Picking speed improved by 66%
• Accuracy improved through reduced manual handling

These improvements have strengthened Codale’s ability to deliver fast, reliable service to contractors.

Workforce and sustainability impact

AutoStore Ports reduce unnecessary motion and physical strain, improving ergonomics and job satisfaction. Integrated cartonization logic supports right-sized packaging, reducing corrugated waste and freight emissions in line with Sonepar’s ESG targets.

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A Platform Built to Scale

AutoStore’s modular architecture allows Robots and Ports to be added without disrupting live operations. This inherent scalability gives Codale confidence that the system will grow alongside its business.

As part of Sonepar’s network of more than 12 AutoStore sites globally, the Las Vegas site now serves as a proven model for future deployments. It demonstrates how high-density automation can deliver speed, reliability, and long-term flexibility at scale across a global distribution network.

Project Specifications

• ‍Installation type: Greenfield‍
• Robots: 11 AutoStore R5 Robots‍
• Workstations (Ports): 6 CarouselPorts, 2 ConveyorPorts‍
• SKUs: 9,700‍
• Grid footprint: 5,500 ft² (511 m²)‍
• Software: Kardex FulfillX WES with cartonization module‍
• Integrated technology and automation:
  AutoStore Goods-to-Person system, intelligent cartonization, guided picking interfaces‍
• Partner: Kardex