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Material Handling Case Studies

See How UNEX Solutions Transform the Supply Chain.

Our material handling case studies provide an informative and insightful look into the significant impact UNEX solutions can have on your operation. Browse our case studies to learn more about applications where UNEX solutions have made a huge impact across the supply chain. Whether you’re in need of dynamic storage solutions like carton flow, flow racks, high-density storage, or you’re looking to improve material flow throughout your facility with portable and permanent gravity conveyors, our case studies will help you discover what’s possible when you work with UNEX. Contact us to connect with a product specialist who can help you create the solutions required for your unique needs. UNEX provides full and free engineering support on all projects!

High-Density Storage

SpeedCell high-density storage compresses rows of shelving into highly organized, space-saving storage that increases SKU capacity, improves pick speed, and reduces travel time. Browse the case studies to see how operations turned unused space into efficient pick zones and boosted accuracy without expanding their footprint.

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Goodwill

Facing growth and space constraints, Goodwill Industries of Central & Southern Indiana implemented UNEX SpeedCell. The upgrade expanded storage by 30%, cut 3+ miles of wasted travel, and created an agile eCommerce facility that’s efficient and mission-driven.
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Overton’s

Overton’s, the world’s largest watersports dealer, added thousands of SKU locations with UNEX SpeedCell without expanding its footprint. The solution boosted efficiency 20–30%, increased pick locations 150%, and drove major gains in daily order output.
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Carton Flow

UNEX carton flow maximizes productivity by ensuring FIFO inventory rotation, reducing picker strain, and delivering up to 150% faster throughput in order fulfillment environments. Explore the case studies below to see how real companies used carton flow to overcome space constraints and speed up their pick operations.

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Atlas Distributing

To keep up with the craft beer boom, Atlas Distributing turned to UNEX SpanTrack Keg Flow. The system boosted keg capacity, avoided the need for a 5,000 sq. ft. cooler expansion, and organized thousands of SKUs into a streamlined, accessible setup.
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Fresh Direct

One of New York’s online grocery leaders relies on UNEX SpanTrack for faster fulfillment. By upgrading 4,000 product slots, Fresh Direct created room for hundreds of SKUs, improved pick rates, and kept 63,000+ weekly orders flowing, averaging 8.5 lines per order.
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Cutter & Buck

Cutter & Buck built a high-tech distribution center in Canada to serve 25,000 pick locations and 1M+ apparel items. With 4,000+ UNEX SpanTrack Wheel Beds, the retailer maximized space, improved flow, and created a lean, efficient operation for faster fulfillment.
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Diversity Vuteq

Heavy totes and changing components pushed Diversity Vuteq to upgrade with UNEX SpanTrack steel rollers. The durable system improved ergonomics, boosted productivity, and allowed the automotive supplier to deliver 6,500 parts per day seamlessly.
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ThermoFisher Scientific

ThermoFisher Scientific redesigned cooler and freezer areas with UNEX SpanTrack to optimize product flow. The upgrade boosted slotting flexibility, improved accuracy, and increased pick efficiency by 45%, creating a faster, more productive fulfillment operation.
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Grocery Distributor

Rather than expand freezer space, a national wholesaler turned to UNEX SpanTrack Wheel Beds. Hundreds of SKUs were added, density increased, and picker productivity jumped 17%, all while keeping flexibility for shifting inventory.
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Capital Candy

Even with 70,000 sq. ft. across three warehouses, Capital Candy needed more capacity. With UNEX SpanTrack, Roller Rack, and Shelf Track, they added 1,000 SKUs, improved pick rates 35%, cut labor costs, and eliminated rotation issues for smoother operations.
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Capital Candy 2.0

Capital Candy turned to UNEX SpanTrack, SpeedCell, and Gravity Conveyor to expand capacity without adding square footage. The upgrades created space for 3,600 more cases and 900 new SKUs, helping the wholesaler boost efficiency and keep pace.
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Pine State Trading Co.

To handle 10,000+ SKUs in a new facility, Pine State Trading Co., a leading C-store distributor, chose UNEX SpanTrack. The carton flow system eliminated hang-ups, maximized space, and provided flexibility to meet evolving C-store demands.
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Southern Glazer's

Southern Glazer’s, the nation’s largest wine & spirits distributor, partnered with UNEX to consolidate operations and maximize space. With SpanTrack carton flow, they achieved industry-leading throughput while nearly doubling productivity and accuracy.
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Food Wholesaler

A national food distributor tackled explosive SKU growth with UNEX storage solutions. By redesigning pick lines with pallet rack walk-throughs and mobile 'Pick Tunnel Carts,' they cut picker travel time by 80% while boosting space, efficiency, and throughput.
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Smart & Final

Smart & Final revamped its Port Stockton Foods distribution center with a vertical UNEX SpanTrack solution. Running carton flow from floor to ceiling maximized freezer space, increased SKU capacity, and streamlined stocking for greater efficiency and cost savings.
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Maletis Beverage

Maxed-out capacity and inefficient floor-stored kegs slowed Maletis Beverage. With 144 lanes of UNEX SpanTrack Keg Flow, they optimized space, created room for thousands of SKUs, and improved keg handling for safer, more efficient operations.
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Flow Racks

FlowCell flow racks provide modular, durable, and ergonomic storage that supports Lean initiatives, helping manufacturers and distributors save space, cut labor costs, and boost picking efficiency. The customer stories below highlight how organizations reconfigured workflows with Flow Racks to increase output without expanding their footprint.

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Darn Tough Vermont

Producing 9M+ socks annually takes precision. Darn Tough Vermont optimized its busy facility with UNEX SpanTrack and FlowCell. From feeding knitting machines to streamlining packing, these carton flow solutions improved storage, flow, and efficiency.
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HelloFresh

HelloFresh expanded meal-kitting capacity from 18 to 28 lines without adding space using a custom UNEX FlowCell solution. The modular flow racks improved ergonomics, streamlined replenishment, and created room for growth while keeping fulfillment precise.
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BraunAbility

BraunAbility, a leading maker of wheelchair-accessible vehicles and lifts, boosted productivity with UNEX FlowCell. Replacing pipe-and-joint structures, the modular racks maximized space, improved flow, and supported fast-moving assembly operations in the same footprint.
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Daimler Trucks

At Daimler Truck's NC facility, cardboard box sub-assembly slowed production. UNEX replaced it with 40 FlowCell workstations and 2,600 SpanTrack lanes, creating an organized supermarket system that eliminated waste and boosted throughput.
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Toyotetsu

Toyotetsu’s Ontario plant faced a twofold production increase and turned to UNEX for a complete storage system. The solution freed 10% more floor space, and created organized bin locations to keep growth on track without new construction.
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Aubuchon Hardware

A family-owned hardware chain with 120 stores improved warehouse efficiency with UNEX FlowCell and SpanTrack. The solution ensured FIFO rotation, reduced mispicks, and increased picking speeds 50%, keeping shelves stocked and customers happy.
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Adient LLC

To boost output from 55 to 60 jobs/hour, Adient LLC needed flexible assembly solutions at its 125,000-sq.-ft. Georgia plant. Forty-one UNEX FlowCell workstations delivered modular, reusable racks that maximized space and met just-in-time production demands.
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George J. Falter

George J. Falter, a longtime candy and C-store distributor, expanded capacity with 32 bays of UNEX carton flow and 45 shelving units. The system created three pick lines for 3,000 SKUs, maximizing space, boosting pick facings, and increasing picker productivity.
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Android Industries

As a GM supplier, Android Industries needed just-in-time precision. With 22 FlowCell workstations from UNEX, installed in a single day, they optimized production flow, boosted efficiency, and ensured the company could meet GM’s just-in-time demands.
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Conveyors

UNEX Gravity Conveyor systems are custom-built for smooth product movement, cutting downtime and labor costs while improving throughput in assembly, warehousing, and logistics operations. Read the case study below to learn how facilities used Gravity Conveyors to eliminate bottlenecks and streamline material handling.

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Williams Distributing

When Williams Distributing consolidated cabinetry operations into a 90,000-sq.-ft. warehouse, old carts and dollies weren’t cutting it. UNEX Gravity Conveyors improved throughput, reduced product damage, and streamlined movement across the facility.
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