The shoe manufacturer Crocs has automated its logistics processes in Dayton, Ohio (USA) to a greater extent and aligned them to the requirements of e-commerce. Part of the new system is a bag sorting system from Ferag AG. With 18 manual loading and 153 unloading stations, 736 switches and almost eight kilometers of lines, the US order is one of the largest Skyfall pocket sorter projects that Ferag has ever implemented.
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The project is directed by system integrator Bastian Solutions, a Toyota Advanced Logistics company. First, the existing distribution center was expanded by over 70,000 square meters. In a further phase, the Skyfall system will now be equipped with 33,500 sorter pockets, which, thanks to the new U-turn switch, function as a dynamic, constantly rotating circulation buffer. Commissioning is planned in several stages by August 2022.
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In combination with an upstream AutoStore warehouse, the new facility is expected to support Crocs’ strategic business and growth plans for the next few years at up to 40,000 units per hour. At the same time, the Skyfall system can be easily scaled if required, used for processing returns and adapted to changing purchasing behavior, new order profiles and seasonal fluctuations. Changes within the Crocs product line are also possible.
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