BlueStar deploys Exotec Skypod system at distribution center

Exotec's Skypod ASRS system installed in a warehouse, with a blue BlueStar banner hanging in the foreground.
The BlueStar deployment includes 20 Skypod robots and racking with 23,000 bins. | Source: Exotec

BlueStar Inc., a global distributor of digital identification, mobility, point-of-sale, and RFID technologies, wanted to increase performance, flexibility, safety, and efficiency in its warehousing operations. It chose Exotec to deliver the Skypod warehouse automation system in its distribution centers in Europe and the U.S.

With more than 50 locations worldwide, BlueStar provides vetted specialty hardware and software to a network of value-added resellers, managed service providers, system integrators, and independent software vendors across all verticals. The Hebron, Ky.-based company serves 13,000 resellers annually across 70 countries.

Since opening its EMEA (Europe, the Middle East, and Africa) Distribution Centre in Eindhoven, the Netherlands, in 2019, BlueStar said it has experienced consistent growth. To meet increasing demand and customer expectations, the company decided to expand its infrastructure and optimize its processes by engaging Exotec.


 

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Skypod optimizes picking, says Exotec

Exotec said its goods-to-person (G2P) system supports operators in picking orders. BlueStar’s system includes 20 Skypod robots, racking with 23,000 bins, three picking stations, and one bin interface. The automated storage and retrieval system (ASRS) is adaptable to specific customer needs.

The Skypod autonomous mobile robots (AMRs) function as a fleet supporting the operators to prepare orders faster, said Exotec. The company programs the robots to prioritize the most urgent orders received from its software to ensure the fastest and most efficient processing of orders.

Skypods operate in an enclosed and human-free environment, reducing the risks associated with pedestrian traffic in the warehouse, it added.

The robots bring bins to Exotec’s picking stations, which can be used for order picking, replenishment, and stock checking. Each station includes a ramp, a screen, and various scanners that allow Skypod robots to present bins and trays to operators for ergonomic picking of up to 400 lines per hour.

These stations allow operators to stay in one place to pick goods, instead of walking several miles daily to grab items across the warehouse.

“We take pride in supporting BlueStar’s optimized expansion and enhancing workplace safety for its employees,” said Jan Heijblom, a senior sales executive at Exotec.

BlueStar sees early results

“We are very pleased with the robust and efficient implementation of the Exotec solution,” said Manel Baranera, EMEA chief operating officer at BlueStar. “This investment has significantly enhanced our logistical capabilities, enabling us to process daily orders efficiently, regardless of their volume or complexity.”

BlueStar said the Skypod for order picking and packing has significantly reduced the time between item retrievals and reduced warehouse traffic by 60%. This has resulted in a safer environment and created a less physically demanding work environment for the operators.

With offices in Lille, France, and Atlanta, as well as in Munich, Tokyo, and Seoul, Exotec said the world’s largest brands use its hardware and software to improve efficiency, resilience, and working conditions in warehouses. The company won a 2024 RBR50 Robotics Innovation Award for the deployment of its Skypod modular storage system at Lane Automotive.

Written by

Automated Warehouse Staff