Case Study: iHerb doubles throughput and boosts labor efficiency 300% with Bastian Solutions' automated order-fulfillment system

Online Wellness Retailer iHerb Doubles Throughput Capacity with New Automated Order-Fulfi llment Facility

iHerb, the online wellness retailer, needed a new East Coast fulfillment center to handle rising order volumes and replace a labor‑intensive batch‑picking process. Bastian Solutions was engaged to design and install an automated pick‑to‑order and material‑handling solution — including goods‑to‑person robotic picking, conveyors, put‑to‑light workstations, carton erectors and integrated RF scanning — to harmonize machine and human tasks and speed time‑to‑market.

Bastian Solutions’ implementation enabled iHerb to process individual orders end‑to‑end in as little as 15 minutes and increase throughput from roughly 10,000 orders to 15,000–20,000 orders per shift while maintaining about 99% accuracy. The new system improved labor efficiency by approximately 300% (aisle operators can pick up to 800 items/hour), and the control‑integrated material‑handling solution delivered measurable capacity and speed gains for iHerb.

iHerb

Kurt Cheek

Director of Operations