Case Study: Cabela’s achieves increased throughput to meet seasonal demand with Bastian Solutions

Cabela's - Customer Case Study

Cabela’s, the global outdoor outfitter, faced heavy seasonal demand and needed an ergonomic, high‑throughput solution for large and heavy products to support expanded retail and e‑commerce volumes and to be operational by the September–December peak season. Cabela’s engaged Bastian Solutions to automate a new distribution center in Wheeling, West Virginia, using technologies such as Hytrol ProSort sorters, extensive conveyor systems, a multi‑level pick module, put‑to‑light, mezzanines, scanners, scales and control/HMI systems.

Bastian Solutions implemented a phased automation build‑out—including over 25,000 feet of conveyor, double‑sided and ship‑alone ProSort sorters, a 240‑position put‑to‑light system, extendable dock loaders, and a warehouse control system—which increased throughput (catalogue sorter to 94 CPM; ship‑alone sorter to 30 CPM), improved ergonomics for handling heavy items, and reduced transportation costs by enabling east‑coast orders to ship from Wheeling instead of Nebraska or Wisconsin. Bastian Solutions’ system met the peak‑season timing and delivered measurable gains in speed, safety, and shipping efficiency.

Cabela's