Case Study: Elsevier doubles throughput, reduces labor and optimizes warehouse space with Bastian Solutions

Elsevier - Customer Case Study

Elsevier, a textbook publisher and distributor, faced growing volumes, inefficient space use, frequent system jams and maintenance issues, and reliance on seasonal temporary labor. Bastian Solutions was engaged to deliver an automated warehouse redesign and add-on systems — including a 7,400 sq ft mezzanine, outsourter machines, Active Roller Belt (ARB) and accumulation conveyors, weigh scale and Intermec scanners, sawtooth merge and a human machine interface (HMI) — to increase capacity and operational visibility.

Bastian Solutions reconfigured the packaging area and installed the automated sortation and control technologies, doubling throughput from about 14,000 to roughly 28,000 orders per day, reducing labor needs by 18% (from 110 to 90 employees), and greatly cutting downtime, jams and product damage. The added HMI improved conveyor visibility and equipment control, delivering measurable space, labor and reliability improvements under the Bastian Solutions implementation.

Elsevier