Thames Logistics — London Distribution Centre

Thames Logistics ran a 24,000 m² ambient DC for a UK supermarket at 98% of pallet capacity and fewer than 310 picks per hour per picker. SKU count had grown 37% in 18 months, but the original 2008 racking layout was optimised for single-SKU pallet moves — and a damage audit revealed 240+ red-rated impacts with no remedial plan on file.

Kentron modelled the SKU file against MHE, cube and velocity, then rebuilt the DC in three phases — ambient zone, pick mezzanine and VNA high-bay — while the client continued to ship live. Every phase was signed off by an SEMA-approved inspector and re-documented for insurance review.

Throughput more than doubled, picker productivity rose from 310 to 680 picks per hour, and the client recovered its programme capex within 19 months. Annual SEMA inspection and a spares contract are in place for the full asset life.