New Grand Prairie distribution center extends a proven automation strategy, applying years of operational experience and collaboration to support continued growth.
Global intralogistics and warehouse automation specialist Kardex has reached another milestone in its long-standing partnership with Cutter & Buck, following the official opening of the apparel company's new distribution center in Grand Prairie, Texas.
The new facility represents a significant expansion of Cutter & Buck's North American fulfillment network and marks the next phase of an automation strategy developed in collaboration with Kardex. Building on the success of its original AutoStore™ system in Renton, Washington, Cutter & Buck has continued to invest in scalable automation to support increasing order volumes, expanding inventory requirements and evolving customer expectations.
Rather than simply replicating its original system, Cutter & Buck and Kardex have applied years of operating experience, performance data and shared knowledge to design a new automated distribution operation around the company's current and future fulfillment requirements.
Cutter & Buck's automation journey with Kardex began at its Renton, Washington, distribution center, where the first Kardex-deployed AutoStore system went live in July 2023.
Featuring more than 34,000 storage bins, 54 robots and Kardex FulfillX warehouse execution software, the system was designed to maximize available storage space, improve picking efficiency and accuracy, increase throughput and reduce reliance on seasonal labor.
As Cutter & Buck's business continued to grow, so did the demands on its fulfillment operation. The company subsequently expanded its Renton AutoStore system, adding 9,962 storage bins, additional ports and infrastructure to accommodate more SKUs and provide greater operational flexibility.
This progression from initial implementation to expansion provided both companies with valuable operational insights that helped inform the development of the new Texas facility.
At the heart of the Grand Prairie distribution center is a second AutoStore goods-to-person system designed and integrated by Kardex.
The new solution includes:
Designed to support increasing fulfillment demands, the system has a target throughput of 1,256 bin presentations per hour, with simulation results averaging 1,284 bin presentations per hour. Its modular architecture also allows robots and ports to be expanded independently as operational requirements evolve.
Kardex's involvement extends beyond the AutoStore system itself. An integrated conveyor solution connects automated picking with downstream fulfillment processes, including embroidery, order routing, Print & Apply and shipping.
Together, these technologies create a connected fulfillment environment designed to support Cutter & Buck's mix of blank and decorated apparel orders while providing the flexibility to accommodate future growth.
The Grand Prairie opening represents more than the deployment of a second AutoStore system. It reflects how Kardex and Cutter & Buck have continued to build on their shared experience, applying lessons from an existing operation to the design of new fulfillment infrastructure.
Across the original Renton implementation, subsequent expansion and new Texas facility, the partnership has evolved from addressing an immediate operational challenge to supporting a broader, long-term distribution strategy.
“What makes this milestone particularly meaningful is everything that led to it,” said Fred Fox Jr., President of Kardex AS Solutions Americas. “We started by working with Cutter & Buck to solve a specific fulfillment challenge in Renton. As their business grew, we expanded that system together. Now we're taking years of shared experience and applying it to an entirely new operation in Texas. That's what a strategic automation partnership should look like – continuing to evolve the solution as the customer's business evolves.”
The new Grand Prairie distribution center provides Cutter & Buck with a scalable foundation for continued growth, while demonstrating how AutoStore technology, Kardex FulfillX and integrated fulfillment solutions can evolve alongside changing business requirements.
For Kardex, the project reinforces the value of combining automation technology, software expertise and long-term customer collaboration to deliver solutions designed not only for today's operational needs, but for what
Kardex is a leading global partner for intralogistics solutions in an attractive and growing market. The Group offers premium automated products, standardised systems, and life cycle services that guarantee high availability and low total cost of ownership. Kardex provides an intelligent entry into automation with its dynamic storage and retrieval systems, offers integrated material handling systems, small parts storage systems, and automated high-bay warehouses, and acts as a global AutoStore™ partner, offering flexible and modular storage and order fulfilment solutions. The Group employs around 2,900 people in over 30 countries. Kardex Holding AG has been listed on the SIX Swiss Exchange since 1989.
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