Fueling Peak Performance: How EAS Supplements Built an Order Fulfillment Powerhouse with System Integration
The Client: EAS Supplements
EAS develops sports nutrition products for athletes and performance-focused consumers. As demand grew across North American and global channels, order volume outpaced the capabilities of its legacy warehouse infrastructure.
To keep service levels high and support future growth, EAS needed a faster, more accurate, and more scalable fulfillment system.
The Challenge
- Legacy Infrastructure Constraints: A single forklift and basic conveyor setup could not keep pace with rising order complexity and volume.
- Manual-Handling Bottlenecks: High dependence on manual movement slowed throughput and increased risk of picking and routing errors.
- Scalability Pressure: Existing operations lacked the capacity and process control required for sustained growth.
- Service-Time Expectations: EAS needed to reliably meet same-day shipment requirements for fast-turn orders.
- Ergonomic and Labor Efficiency Concerns: Repetitive handling and excessive walking increased strain and reduced productivity.
The Solution
FloStor designed and integrated a new 141,000 sq ft distribution center architecture that connected guided picking, automated routing, shipment verification, and carrier-specific manifesting into one coordinated flow system. The focus was not just equipment replacement, but end-to-end execution redesign.
The solution combined high-speed conveyance, scan-driven sort logic, and operator-guidance technology to improve throughput, reduce errors, and support same-day fulfillment targets.
Systems Used
- 7-Zone Production Picking Lines: Zoned pick workflow supported controlled order progression and efficient multi-box order handling.
- Touchscreen and Handheld Scan Guidance: Operator-directed picking with digital instructions improved speed and transactional accuracy.
- Integrated Conveyor Network: Gravity, horizontal power, and live roller conveyors moved orders continuously through pick, sort, verify, and manifest stages.
- AccuSort Scan and Diverter Routing: Automated barcode-driven sortation directed cartons into carrier-specific lanes using power-pivot diverters.
- Verification and Manifest Workstations: Final-check stations with ball transfer tables enabled accurate sealing and carrier handoff preparation.
- Ergonomic Process Design: Layout and handling flow were optimized to reduce unnecessary travel and keep most lifts within safer ergonomic ranges.
The Power of Integration in Action
FloStor’s integration role unified transport hardware, scan technology, routing logic, and workstation execution into one synchronized fulfillment engine. This removed stop-and-start handoffs and improved order flow predictability from picking through carrier assignment.
Implementation was staged to maintain live shipping continuity, allowing EAS to continue customer fulfillment while the upgraded system came online.
“The installation and operation has gone extremely well.” – Shelly Phillips Metz, Vice President of Logistics and Distribution
The Results
EAS transformed warehouse operations from a manual throughput limiter into a higher-capacity, higher-accuracy distribution platform. The redesigned process improved shipment reliability and positioned the business for continued growth without sacrificing service speed.
By combining intelligent routing with operator-guided execution, EAS gained stronger control over order quality and same-day fulfillment performance.
Key Performance Gains
- Throughput Capacity: New operation runs at approximately 1,800 cases per day with additional headroom for growth
- Same-Day Fulfillment Capability: Orders received by 2:00 p.m. can be shipped same day, complete and accurate
- Order Quality Improvement: Wrong shipments decreased through integrated scanning and verification checkpoints
- Labor and Ergonomic Efficiency: Reduced walking distance and safer handling zones improved operator productivity and comfort
Why This Worked
This implementation worked because EAS and FloStor treated fulfillment as a system-level redesign rather than a simple equipment upgrade. Picking, routing, verification, and carrier handoff were engineered to operate as one continuous process.
- End-to-End Integration: Physical movement and digital decision logic were synchronized to reduce delays and handoff errors.
- Scan-Driven Accuracy Control: Guided picking and automated route assignment improved consistency under higher volume conditions.
- Operationally Safe Deployment: Phased installation preserved continuity of live fulfillment during system transition.
- People-Centered Performance Design: Ergonomic handling and reduced travel supported sustained output quality.
Related Services
- System Integration and Controls Engineering
- E-commerce and Distribution Flow Modernization
- Conveyor Sortation and Verification Architecture
- Phased Fulfillment Implementation and Lifecycle Support