Small Automation, Big Impact: Problem-Solving Through Entry-Level Material Handling Automation Solutions

Joe Campbell | 5 February 2025

When we think about material handling automation, we often picture large-scale systems requiring significant capital and time investments. Yet, small-scale integrations can deliver transformative results for targeted challenges, offering a path to efficiency that many organizations overlook. Entry-level automation can substantially improve efficiency, accuracy, and scalability—all without overhauling the entire operation and minimizing the risk to the business. These solutions are about doing more with what you have, like incorporating carton flow racking to streamline picking or ergonomic packing stations to enhance worker efficiency, unlocking untapped potential, and preparing for future growth.

At Bastian Solutions, we’ve seen firsthand how strategic small-scale automation can drive big results. By addressing specific operational pain points, businesses can solve immediate problems while setting the foundation for long-term success.

The Value of Small-Scale Automation

Small-scale automation focuses on implementing solutions tailored to immediate and specific operational needs. These projects don’t require the sweeping infrastructure changes often associated with large-scale automation, making them more accessible for businesses of all sizes.

Here’s why these systems matter:

• Cost-Effective Implementation: Small-scale automation is budget-friendly, often repurposing existing infrastructure and requiring minimal downtime.
• Scalability: These systems provide a foundation for future upgrades, allowing businesses to grow at their own pace.
• Faster Results: With targeted improvements, companies can see tangible outcomes quickly, whether through improved efficiency, accuracy, or throughput.
• Minimal Disruption: entry-level automation typically requires minimal downtime, thus avoiding large scale disruptions to the business.

For many businesses, small-scale material handling automation is a steppingstone—a way to stay competitive in a rapidly evolving market while managing resources wisely. Let’s look at two examples of how these solutions have made a tangible difference.

Case Study: Sur La Table’s Journey to Operational Excellence

Scaling Fulfillment with Targeted Automation

Sur La Table, a premium culinary retailer, faced a common issue in modern omni-channel retail: the challenge of scaling e-commerce operations to meet surging demand. During peak seasons, their fulfillment operations struggled to keep pace with order volumes exceeding 150,000 units daily. Manual processes were inefficient and error-prone, creating bottlenecks in order consolidation and shipment.

Crafting the Solution

Bastian Solutions worked closely with Sur La Table to develop a phased approach that addressed these challenges while maintaining budgetary constraints. Key elements included:

• Mobile picking systems with RF scanners to enhance accuracy and reduce errors.
• A conveyor system featuring zero-pressure accumulation to optimize the flow of goods.
• A three-level pick module designed to maximize space and streamline the picking process.

The Impact

The results were immediate and significant. Through a phased implementation, Sur La Table minimized costs while boosting capacity to handle up to 200,000 units daily. By reusing parts of their existing conveyor system, they achieved operational efficiency without unnecessary expenses, ensuring their system could adapt to future growth demands.

Read the Full Case Study

Case Study: How Nine Line Apparel Streamlined Operations for Growth

Meeting the Demands of Rapid Growth
As a veteran-owned lifestyle brand, Nine Line Apparel was rapidly growing and expanding its product offerings. With this growth came the need to enhance their operational workflows and storage solutions to meet increasing customer demand effectively. Their existing systems, while functional, were reaching capacity, and limited indoor storage posed challenges in managing inventory efficiently.

Developing the Approach

To create a more organized and scalable operation, Bastian Solutions implemented several targeted upgrades:

• Carton flow racking to streamline inventory picking.
• Selective and pushback racking systems to optimize storage for dynamic and static inventory.
• Ergonomic packing stations to improve worker comfort and productivity.

Delivering Results

With these updates, Nine Line Apparel transformed its operation. Indoor storage capacity expanded to accommodate up to 1,100 pallets and 6,000 SKUs, eliminating the need for outdoor storage. Inventory management improved significantly, reducing lead times and enabling faster order fulfillment. These changes provided a scalable foundation to support their continued growth.

Read the Full Case Study

Key Insights: Lessons from Small-Scale Material Handling Automation Success

The experiences of Sur La Table and Nine Line Apparel highlight some critical takeaways about the role of small-scale automation in material handling:

1. Start Small, Scale Strategically: Automation doesn’t have to be all-or-nothing. Beginning with targeted improvements allows businesses to address immediate challenges while setting the stage for future expansion.
2. Leverage Existing Infrastructure: Reusing and optimizing current systems can significantly reduce costs while maintaining operational continuity.
3. Focus on Pain Points: Identifying and addressing specific operational bottlenecks delivers quick wins and measurable results.
4. Partner for Success: A tailored approach from an experienced material handling automation integrator ensures that solutions align with business needs and goals.

Partnering with an experienced material handling automation integrator like Bastian Solutions ensures that your automation journey is guided by expertise and tailored to your unique needs. Integrators bring a comprehensive understanding of system design, implementation, and optimization, helping you seamlessly integrate new solutions into your existing operations. From evaluating your specific challenges to delivering scalable, cost-effective systems, working with a trusted partner means you’ll have a dedicated team focused on maximizing your efficiency and setting your business up for long-term success.

Start Your Small-Scale Material Handling Automation Journey

Small-scale automation proves that you don’t need a massive investment to see a significant impact. Businesses like Sur La Table and Nine Line Apparel achieved greater efficiency, improved accuracy, and readiness for growth by addressing specific challenges with targeted solutions.

Are you ready to explore how small-scale automation could benefit your operations? Talk to a Bastian Solutions engineer today to start your journey toward more intelligent, efficient material handling.

Author: Joe Campbell