Automated Jewelry Order Fulfillment for E-commerce

As online shopping demand continues to surge, e-commerce businesses face a major challenge: how to process orders efficiently, especially when demand fluctuates sharply during promotions or TV shopping campaigns.

An e-commerce distribution center in Canada addressed this challenge by deploying an automated storage and order fulfillment solution, achieving 54% labor reduction, 75% floor space savings, and up to 600% productivity increase.

Challenge: Demand Volatility and Workforce Optimization

The company operates a 300,000 ft² warehouse, processing an average of 10,000 orders per day. Jewelry accounts for 20% of revenue but experiences extreme order fluctuations depending on TV shows or marketing campaigns.

Staff allocation became difficult—some days saw only a few hundred orders, while peak days exceeded 2,000 order lines per shift. In addition, traditional open-rack jewelry storage within limited space could no longer keep pace with annual growth.

Solution: Automation with Intelligent Vertical Carousel Systems

The implemented solution included:

• 3 Vertical Carousel Modules, nearly 9 meters high
• Kardex Power Pick System inventory management software
• Batch picking stations capable of processing 120 orders simultaneously

This technology is ideal for small, high-value items such as jewelry, coins, and electronic accessories, delivering:

• Up to 75% space optimization
• 6× productivity increase, reaching 240 order lines/hour/operator during peak periods
• Lower labor costs, requiring only 10 staff instead of 22

Fast, Accurate, and Flexible Order Processing

Jewelry orders are batch-processed using pick-to-light technology, allowing operators to handle 120 orders at once. Each pick is guided and confirmed via lights and visual displays, ensuring:

• High processing speed
• 99.9% picking accuracy
• Minimal waiting time between picking cycles

Ergonomic Benefits and Higher Labor Efficiency

The solution reduces each operator’s working area to just 9.75 m, minimizes bending, and keeps picking zones at ergonomic heights. Employees can work continuously with less fatigue, improving retention and overall job satisfaction.

Flexible Returns Handling and Storage

Returned items are manually inspected and cleaned before being reintroduced into the system. On average, 2,500 returned products per week are processed efficiently thanks to advanced software and equipment.

For items with sudden demand spikes (e.g., promotions), products can be temporarily stored on pallets outside the carousel and reloaded later—enhancing flexibility and responsiveness to market demand.

Conclusion

Investing in smart warehouse automation and order fulfillment solutions enables e-commerce businesses to:

• Adapt quickly to demand fluctuations
• Reduce operating costs
• Enhance the end-customer experience

ETEK Intralogistics is proud to deliver advanced storage and warehouse automation solutions tailored to all industries—especially small, high-value products such as jewelry, pharmaceuticals, and electronics.
📩 Contact us to discover the best solution for your business.