Case Study: Prime Distribution Services, Inc. achieves warehouse consolidation and dramatic picking productivity gains with Bastian Solutions

Prime Distribution Services, Inc. - Customer Case Study

Prime Distribution Services, Inc., a third‑party logistics provider in Plainfield, IN, engaged Bastian Solutions to expand its warehouse management capabilities and consolidate multiple Indianapolis facilities into a new 1.2 million sq. ft. site. PDS required a pick module to initially store 300 SKUs (scalable by another 300), an upgraded WMS to support mixed‑pallet builds, and a system able to handle an anticipated 20,000–25,000 cases per 8‑hour shift.

Bastian Solutions implemented three two‑level pick modules (≈200 pick faces each) and deployed ExactaWMS and ExactaWCS alongside pick‑to‑display, EZ Logic zero‑pressure accumulation, a Transnorm mega conveyor merge, an Accusort 9‑sided scan tunnel, and Rockwell RSView HMI with PC‑based Steeplechase conveyor control. The solution consolidated PDS’s operations into the new facility, expanded WMS capabilities, and enabled growth to higher order volumes without adding labor—delivering dramatic gains in operator productivity and throughput.

Prime Distribution Services, Inc.