ProDuo, a distributor of cosmetics, has restructured its European distribution center (DC) in collaboration with Easy Systems to support logistical efficiency and growth.

By consolidating distribution centers in France, Spain, and the Netherlands, and opening an additional warehouse in Ghent, ProDuo’s DC has significantly expanded. The new 8,000 m² warehouse is the inbound location, while the original warehouse is used for pick & pack operations. A shuttle truck ensures inventory movement between the two locations.

The efficiency gained by ProDuo through Easy Systems’ installation is evident in the outbound warehouse. The automated system with flat belt conveyors and roller conveyors forms the heart of the operation. Easy Systems’ solution also needed to integrate with the WMS. The installation supports both the retail and e-commerce channels of ProDuo. Picking for stores is done in cardboard boxes, while e-commerce orders are processed in reusable crates. For the latter, Easy Systems installed a destacker. For each order, the machine introduces a new crate into the system, which is then transported to the picking zone.

The warehouse operates with three picking zones: large items (non-conveyables), small fast movers under the mezzanine, and slow movers on the mezzanine. Products are efficiently picked and sorted, resulting in shorter walking distances and higher productivity. The boxes for retail points arrive in a consolidation zone via Easy Systems’ conveyors. After adding dunnage, an automatic taper seals the boxes. The boxes are then collected on pallets, with each pallet organized by store for shipment.

The reorganization has led to cost savings and improved efficiency. ProDuo expects a 25% efficiency improvement over time. The consolidation has not impacted delivery times to stores, and the new approach supports the growth of e-commerce activities.