Codale, a regional subsidiary of global business-to-business electrical distributor Sonepar, experienced a high volume of walk-in traffic from electrical contractors at a new facility. It needed fast and convenient walk-in service that also operated within space constraints near the Las Vegas Strip. The company turned to Kardex Solutions for automation.
Founded in 1975, Codale Electric Supply offers electrical systems for industrial, commercial, and residential needs. The Salt Lake City-based company is part of Sonepar, an independent family-owned group that recorded sales of €33.3 billion ($36 billion U.S.) in 2023.
Sonepar has a presence in 40 countries and 45,000 associates. It entered the U.S. market in 1998 and has more than 570 locations nationwide and 12,800 associates.
The company said its new central distribution center (CDC) unites three locations under one roof and provides a model for future high-density, data-driven Sonepar sites across the U.S.
Kardex integrates systems in a compact design
Codale deployed a goods-to-person (G2P) system at at its CDC serving the Las Vegas market. It combines Kardex’s FulfillX warehouse execution system (WES) software with AutoStore’s automated storage and retrieval system (ASRS).
The ASRS compresses nearly 10,000 SKUs into a 5,500-sq.-ft. (510.9 sq. m) area, reducing floor space requirements by 80%, noted Kardex. The CDC manages two distinct workflows for bulk regional replenishment across the Southwest region and same-day will call orders from electrical contractors in Las Vegas.
The AutoStore system includes 25 R5 robots delivering small-pick electrical items such as receptacles, fittings, safety gear, and tools to six picking ports, and carrying out replenishment from two inbound ports.
Kardex said the ASRS, the WES, and its Intuitive Picking Assistant (IPA) user interface are fully integrated into Sonepar’s systems for full enterprise resource planning (ERP) connectivity.
FulfillX manages processes in real time
FulfillX manages every process, from storage allocation to carton selection, using real-time data to sequence orders and balance workloads automatically, explained Kardex. The WES maintains throughput and order accuracy across multiple workstations even as demand fluctuates, it said.
The Kardex IPA interface guides operators through each step of the picking and packing process with 3D visual instructions. This achieves higher accuracy and faster throughput with minimal training, while the ergonomic station design reduces fatigue and enhances job satisfaction, the company claimed.
An intelligent cartonization module within FulfillX calculates the most efficient box size and packing layout for orders before picking begins. This eliminates guesswork, minimizes packaging waste, maximizes truck utilization, and cuts dimensional-weight shipping costs, asserted Kardex.
The company said its module also contributes towards Sonepar’s sustainability goals of reducing waste and greenhouse gas emissions without adding complexity.
Sonepar, Codale report increased efficiency
The unified AutoStore system with Kardex’s FulfillX significantly increased throughput from Day 1, according to the companies. Standard order processing has risen by 12%, and “will call” order processing has risen by 20%, with higher accuracy rates, minimized manual touches, and real-time visibility.
“With Kardex, we’ve built a system that sets us up for long-term success, while meeting our current need to quickly turn around orders for electrical contractors and other customers,” said Dana Mouritzen, chief operating officer and president for the East Region at Sonepar USA.
“We’re able to serve walk-in customers in just minutes and have the flexibility to adjust to an influx of orders for a large-scale project with reliable, accurate service,” he added. “Customers get exactly what they need when they need it; that’s the bottom line.”
Kardex added that the AutoStore grid’s compact design reduces building costs, energy use, and internal travel time, while ensuring quick access to every SKU. The system’s modular architecture allows for more robots and ports to be added, supporting projected growth for the next decade while managing both rising order volumes and increased SKU diversity.
“This project is a great example of how AutoStore technology enables intelligent fulfillment at scale,” stated Mike Dickson, president of the Americas at AutoStore. “Together with our partner Kardex, we’re helping Sonepar build a fast, space-efficient operation that is ready to grow with their business.”
See Kardex at Manifest 2026
“This project reflects exactly what Kardex is committed to delivering: automation that enables our customers to grow with confidence,” said Fred Fox, president of Kardex Solutions. “Sonepar recognized that future-ready fulfillment requires more than storage density; it demands intelligent workflows, real-time orchestration, and a seamless customer experience.”
“[Its] Las Vegas operation is now one of the most advanced distribution environments in the industry, and we’re honored to help bring that vision to life,” he said.
Kardex is exhibiting at the Manifest supply chain and logistics event at Booth 983 at The Venetian in Las Vegas next week. In addition, Kardex, Codale, and AutoStore will show the system in action at an AutoStore Xperience Day at the Las Vegas facility on Feb. 12, 2026. Register here to attend.
Kardex said it provides intralogistics automation, standardized systems, and lifecycle services for high availability and a low total cost of ownership. The Zurich-based company integrates material handling systems, small parts storage systems, and automated high-bay warehouses.
The AutoStore partner also offers modular ASRS and order-fulfillment systems, recently deploying its 100th site. Listed on the SIX Swiss Exchange since 1989, Kardex Holding AG employs around 2,500 people in more than 30 countries.
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