Retail/Entertainment industry

Inteq was entrusted with a complex challenge to design and implement a logistics solution that would support the seamless relocation of a customer’s operational processes from an existing UK distribution centre to a new facility in Ryton, United Kingdom. The transition demanded minimal disruption, high efficiency, and alignment with the client’s logistical, technical, and operational requirements. The customer also required future scalability and continuity of service, meaning the solution had to be robust, modular, and well-supported from both a technical and operational standpoint.

To address the challenge, Inteq engineered a semi-automated system that divided the logistics workflow into interconnected sub-processes, each tailored to support specific operational needs. The design focused on fluidity, speed, and precision, all integrated through a central conveyor system and Inteq’s proprietary IWS Warehouse Control System (WCS).

The sub-processes included:

• Inbound sortation
• Put-away
• Replenishment
• Picking and packing
• Value-added services (VAS)
• Outbound consolidation and loading

Inteq’s system featured 1.1km of Interroll conveyors, providing high-speed material flow throughout the facility. A spiral elevator and two Nerak lifts enabled vertical transport of goods, while five powered flexi-conveyors ensured flexibility for dynamic operations at loading docks.

The 64 Ecom packing benches equipped with Pick-to-Light technology facilitated rapid and accurate order fulfillment. Cognex and RFID scanning systems enhanced real-time tracking and validation of products. Additional components such as a dimension and weigh scanning system ensured accurate parcel profiling, while Axelent safety fencing protected personnel and equipment.

The entire system was supported by robust PLC controls and the IWS WCS, which provided centralised control, monitoring, and data collection, ensuring high-level visibility and responsiveness across all processes.

Inteq successfully delivered the project ahead of schedule and under budget, exceeding client expectations. Despite mid-project design amendments requested by the customer, Inteq adapted swiftly—completing additional design iterations and updated costings without impacting the original delivery timeline.

Following implementation, Inteq secured a maintenance contract that included an on-site engineer during standard operational hours, along with a second engineer during peak periods. This ensured consistent performance, minimised downtime, and allowed for rapid response to any operational issues.

Inteq’s collaborative approach, technical precision, and adaptability enabled a successful transition of operations to the Ryton facility. Through a combination of automation, custom integration, and ongoing support, the client achieved operational continuity, improved efficiency, and a scalable solution for future growth.