Kardex provides Sonepar USA with AutoStore blueprint for distribution centers

Global AutoStore partner Kardex provided an automated offering to Codale, a regional subsidiary of global B2B electrical distribution organization Sonepar.

Kardex said that the goods-to-person system at Codale’s new central distribution center (CDC) serving the Las Vegas market delivers faster fulfillment, higher accuracy and scalability by combining Kardex FulfillX and AutoStore automation.

Consolidating and automating fulfillment on a single, high-density site

Serving a dense urban environment with space constraints, Kardex said that the AutoStore system, orchestrated by FulfillX warehouse execution system (WES) software, provides a high-density system. It compresses nearly 10,000 SKUs into a 5,500-sq-ft footprint, reducing floor space requirements by 80%. The CDC manages two distinct workflows for bulk regional replenishment across the Southwest region, and same-day will-call orders from electrical contractors in Las Vegas.

The creation of the new high-performance CDC brings together all three branches on a single site. Because there is an unusually high volume of walk-in traffic from electrical contractors in Las Vegas, Kardex said that the new facility needed to provide a fast and convenient walk-in service. However, space constraints associated with operating close to the Las Vegas Strip meant Sonepar needed a high-density automation offering. Additionally, the business was expanding rapidly, so it needed a scalable automated system to meet both its current and future needs.

“With Kardex, we’ve built a system that sets us up for long-term success, while meeting our current need to quickly turn around orders for electrical contractors and other customers,” said Dana Mouritzen, COO and President, East Region, Sonepar USA. “We’re able to serve walk-in customers in just minutes and have the flexibility to adjust to an influx of orders for a large-scale project with reliable, accurate service. Customers get exactly what they need when they need it; that’s the bottom line.”

Integrated orchestration for real-time efficiency

Sonepar said that it turned to Kardex to achieve its goals of high throughput, more efficient and accurate order fulfillment, scalability and improved sustainability. The AutoStore system from Kardex features 25 AutoStore R5 units delivering small-pick electrical items like receptacles, fittings, safety gear and tools to six picking ports, and carrying out replenishment from two inbound ports.

The AutoStore system, Kardex FulfillX WES with cartonization module and the Kardex Intuitive Picking Assistant (IPA) user interface are fully integrated into Sonepar’s systems for full ERP connectivity. 

“This project reflects exactly what Kardex is committed to delivering: automation that enables our customers to grow with confidence,” said Fred Fox, president, Kardex Solutions. “Sonepar recognized that future-ready fulfillment requires more than storage density; it demands intelligent workflows, real-time orchestration, and a seamless customer experience. Their Las Vegas operation is now one of the most advanced distribution environments in the industry, and we’re honored to help bring that vision to life.”

Kardex said that FulfillX manages every process, from storage allocation to carton selection, using real-time data to sequence orders and balance workloads automatically, maintaining throughput and order accuracy across multiple workstations even as demand fluctuates.

Operators are guided through each step of the picking and packing process by the Kardex IPA interactive interface via 3D visual instructions, which the company said achieves higher accuracy and faster throughput with minimal training. Kardex added that its ergonomic station design reduces fatigue and enhances job satisfaction.

Compact design and efficiency, with scalability

In a case study published by Kardex, Sonepar found that from day one, the unified AutoStore empowered by the Kardex FulfillX system, has significantly increased throughput.

Standard order processing has risen by +12%, and will call order processing by +20%, with higher accuracy rates, minimized manual touches and real-time visibility. Sonepar said that the compact design of the AutoStore grid reduces building costs, energy use and internal travel time, while ensuring quick access to every SKU.

The system’s modular architecture allows additional robots and ports to be added in the future, supporting projected growth for the next decade, and managing both rising order volumes and increased SKU diversity.

“This project is a great example of how AutoStore technology enables intelligent fulfillment at scale,” said Mike Dickson, president of the Americas, AutoStore. “Together with our partner Kardex, we’re helping Sonepar build a fast, space-efficient operation that is ready to grow with their business.”