ResinDek® Helps Evergreen Scale AMR Operations, Improve Accuracy, and Reduce Staffing Needs

Evergreen Enterprises, a wholesale home and garden décor retailer in Richmond, Virginia, implemented autonomous mobile robots (AMRs) to improve warehouse efficiency but encountered flooring problems on the main warehouse floor. Their worn, damaged floors prevented AMRs from traveling smoothly, generating dust and debris. Additionally, the company had previously relied on 90 employees manually picking orders but struggled to scale during peak seasons while maintaining order accuracy.

The Solution: Evergreen ruled out removing existing flooring or pouring new concrete due to cost and operational disruption and instead chose ResinDek mobile robot flooring panels from Cornerstone Specialty Wood Products. The panels were installed directly over the existing floor and could handle dynamic robot loads up to 5,000 pounds—nearly four times the weight of each fully loaded AMR. Installation was completed in phases to keep operations running, with one side installed in under four weeks.

The Results: With the new flooring in place across 60,000 square feet, Evergreen was able to deploy 100 AMRs, increase their travel speeds, and went from two shifts to one – filling peak order volumes with just 28 people. This solution improved throughput, order accuracy, and overall warehouse efficiency while avoiding the massive costs and downtime of traditional flooring replacement.