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By integrating Exotec’s Skypod® system into its Eindhoven distribution center, BlueStar EMEA has revolutionized its logistics operations. The move allows BlueStar to optimize inventory management across a diverse product range while ensuring high-speed, scalable, and sustainable distribution processes.
About BlueStar EMEA
BlueStar EMEA is a global distributor of Point-of-Sale, RFID, and digital display solutions, providing a comprehensive range of hardware, software, and value-added services. With a network spanning across Europe, BlueStar serves businesses of all sizes by delivering tailored technology solutions. From sourcing and staging to configuration and maintenance, BlueStar ensures its clients receive end-to-end support.
In Europe, BlueStar’s primary distribution center is located in Eindhoven, Netherlands. The company specializes in handling a wide array of products—from compact barcode scanners to large-scale digital displays—making precise inventory management and efficient logistics crucial to its operations.
“Our goal is to stay ahead in a highly competitive market by providing reliable and fast service. The introduction of Exotec®’s Skypod system was a significant step in achieving this vision,” explains Manel Baranera, Chief Operating Officer of BlueStar EMEA.
The Challenge
BlueStar faced multiple challenges in its quest to optimize operations:
- Complex Picking Processes: The Eindhoven warehouse had several distinct picking zones. Orders often required multiple touches, with some products moving between zones as many as five times before final consolidation.
- Labor Shortages: Following the COVID-19 pandemic, the availability and cost of labor became critical concerns, pushing BlueStar to seek automation solutions that reduced dependency on manual processes.
- Scalability and Flexibility: With a product catalog ranging from small consumer devices to large industrial screens, the company needed a system capable of adapting to various product sizes and demand fluctuations.
- Sustainability Goals: BlueStar aimed to minimize the environmental impact of its operations while enhancing overall efficiency.
“We needed a system that not only addressed our operational inefficiencies but also aligned with our sustainability strategy. Exotec’s solution stood out,” adds Baranera.
The Solution
| Robots | Picking Stations | Bin Interface | Storage Bins | Bins/Hour | Rack Height | System Footprint |
| 20 | 3 | 1 | 23,000 | 440/hour | 11,7 m (36 ft) | 1,200 m2 (12,917 ft2) |
Key results
1. Operational Benefits
- Consolidation of picking zones, reducing unnecessary movement and training requirements for operators.
- Enhanced inventory accuracy and minimized manual errors.
- Adaptable storage configurations to accommodate a wide variety of product sizes.
2. Enhanced Efficiency
- Reduced order processing time by streamlining picking operations.
- Optimized warehouse space usage with vertical storage, allowing for more inventory within a smaller footprint.
- Significantly decreased the average number of touches per order, enhancing speed and accuracy.
3. Improved Workforce Dynamics
- Lowered training requirements due to intuitive system design.
- Reduced physical strain on operators by automating repetitive tasks.
4. Sustainability Achievements
- Decreased energy consumption compared to traditional systems.
- Optimized use of resources, aligning with BlueStar’s commitment to environmental stewardship.
“This collaboration marks the beginning of a long-term partnership with Exotec. The flexibility and scalability of the Skypod system align perfectly with our growth objectives”