Modern Material Handling Feature: Automation where it counts at ¹û¶³´«Ã½

Katherine Wroth • September 9, 2024
By deploying a drone-based inventory monitoring solution at its Hillsborough, N.J., facility, ¹û¶³´«Ã½ ¹û¶³´«Ã½Centers, a growing 3PL, has taken license plate accuracy to the next level, helping with order picking and eliminating time spent on manual cycle counts.
  • Slide title

    Write your caption here
    Button
  • Slide title

    Write your caption here
    Button
  • Slide title

    Write your caption here
    Button
  • Slide title

    Write your caption here
    Button
  • Slide title

    Write your caption here
    Button
  • Slide title

    Write your caption here
    Button
  • Slide title

    Write your caption here
    Button
  • Slide title

    Write your caption here
    Button
  • Slide title

    Write your caption here
    Button
  • Slide title

    Write your caption here
    Button

By  at


Extremely high accuracy over sitting in storage is a nice thing to have in a DC, but traditionally it has come at a cost: hours of labor spent hand-scanning bar coded license plates or “LPs” on pallets or cases and then reconciling any discrepancies.


Of course, the cost of not expending labor on LP accuracy is downstream delays in filling orders due to misplaced inventory. Given the choice between unhappy customers or expending some labor on LP counts and inventory adjustments, many operations have chosen some form of LP counting and inventory monitoring.


This dedication to inventory accuracy has long been a pillar of operational excellence for ¹û¶³´«Ã½ ¹û¶³´«Ã½Centers, a  company, explains, ¹û¶³´«Ã½’s vice president of business process optimization.


“LP accuracy is one of our key internal drivers for success at ¹û¶³´«Ã½. The more accurate your inventory is, the more productive you can be—because you don’t have unexpected shortages—so you can just pick orders instead of searching for inventory or having to replenish,” says Rapoza. “Our senior leadership team, Tim ¹û¶³´«Ã½ and Art ¹û¶³´«Ã½, also view high LP accuracy as a driver for employee satisfaction because when it comes time to pick, our associates can execute their work without delay, which contributes to a high level of job satisfaction. As a result, we take LP accuracy very seriously, because it’s good for our customers, and it’s also good for our employees.”


The last couple of years have seen ¹û¶³´«Ã½ ¹û¶³´«Ã½Centers further improve on LP accuracy while removing the cost involved in manual data collection by deploying a warehouse drone solution ( to automate the reading and monitoring of LP labels in storage positions. The system’s software, which uses  provides a dashboard view that compares what the drone missions find against  data.


¹û¶³´«Ã½ doesn’t use the drones at all of its warehouses, but it does use them at six sites to automate the counting of LP bar codes on pallets or to count unique cases with LP bar codes.


A single operator managing a drone mission can capture LPs more quickly and accurately than a team of inventory specialists can with manual scanning. The cost comparison is not even close, Rapoza adds. Manual LP cycle counting costs roughly $1.50 per scan; and the drone system costs around 10 to 20 cents per scan—a fraction of the cost.


The drones have been effective at reading the labels and generating reports that pinpoint any inventory variances with ¹û¶³´«Ã½’s WMS. At sites that use the drones, LP accuracy exceeds 99%, and at one facility in Hillsborough, N.J., where the drones are used to capture LPs on unique cases, the accuracy level has reached 99.9%. The drones are used frequently to keep LP accuracy at a near-perfect level.


“The ease of being able to capture a high volume of LP information with a single drone, compared to using a team of people, means that we can perform LP cycle counts more frequently now, so the inventory variances surface much faster,” says Rapoza. “When we first deployed the drones, we saw a pretty significant spike in inventory variances that we were then able to correct in a much shorter time-frame than if we were just deploying people to count LPs. That helps us keep inventory accuracy optimally high for the sites and areas we’ve deployed them in.”


Targeted use cases


Since 1941, ¹û¶³´«Ã½ has provided 3PL services, including direct-to-consumer (DTC) fulfillment, omni-channel distribution, as well as transportation management and retail compliance for clients.


Customers represent industries including apparel and footwear, health and beauty, consumer packaged goods, consumer electronics, food, candy, grocery and automotive. The company currently has 23 DCs nationwide comprising roughly 7 million square feet, including sites in Greater Boston, New Jersey, New York, Baltimore, Memphis, Dallas and California.


With a motto of, “Big enough to do the job and still small enough to deeply care about your business,” ¹û¶³´«Ã½ adapts its services around the fulfillment needs of its clients. For most of its clients, the WMS used to manage and fulfill orders is based on a system called Synapse (, formerly Zethcon).


The use of Gather AI drones across ¹û¶³´«Ã½’s network is largely focused on reading LPs on pallets, though at its fulfillment center in Hillsborough, N.J., the drones are used to scan LP labels on unique cases of shoes for ¹û¶³´«Ã½’s client Stadium Goods, a sneaker and apparel marketplace. These aren’t the average sneakers one would find at any retail store, but rather, collector and special edition shoes that in some instances might fetch several thousand dollars per pair. Most end-customers are typically buying one pair of unique shoes.


As a result, one shoebox with one pair of shoes typically equates to one case for the vast majority of goods in storage at Hillsborough. An inventory authentication team from Stadium Goods works on site to authenticate each pair of shoes coming in before it is processed and stored by ¹û¶³´«Ã½ associates.


Each case is polybagged at the DC after being authenticated, with a unique LP bar code placed on the bag prior to being placed in very narrow aisle (VNA) storage with selective racking. The site uses a modified auto bagging system with a print-and-apply function (Sealed Air) to automate the process of placing each shoebox into a Stadium Goods branded polybag and applying the LP bar code to it.


While a small percentage of these unique cases hold a few pairs of shoes or other apparel items, the vast majority of the cases/bags hold one pair of shoes. Usually, the Hillsborough location has close to a half-million pairs of shoes or other unique cases for Stadium Goods stored on the 34 aisles of VNA racking. When it comes time to fill orders, the picking is done from the VNA storage by associates on orderpickers.


The Stadium Goods inventory is ideal for drone inventory monitoring, says Rapoza, since each case is a unique, high-value item that needs to be in the location the WMS indicates it will be in, since there is no handy supply of the same SKU in reserve. High LP accuracy is important for all of ¹û¶³´«Ã½’s clients and processes, Rapoza explains, but for Stadium Goods, it’s a must.


“We run the drones in a handful of facilities for different storage mediums, but for Stadium Goods, we had a unique value proposition for the drones, because the end customer is buying a specific pair of shoes, so the LP accuracy has to be near perfect,” Rapoza says. “If you think about it, we need to pick a specific pair of shoes, and if those shoes aren’t in the exact location where our WMS system says they should be, now you have to go find that case in a sea of a half-million pairs of shoes.”


Before deploying the drone solution, ¹û¶³´«Ã½ maintained a high level of LP accuracy for Stadium Goods by manual cycle counting by ¹û¶³´«Ã½’s team of inventory control specialists. Now, however, the drones automate the data capture piece, with one inventory control specialist able to manage each drone flight, rather than needing a whole team of people to go out to periodically scan all the LPs in a section of the VNA storage.


Importantly, adds Rapoza, the drones aren’t only a time saver for the inventory team.


“Yes, the drone solution eliminates the need to have our inventory control associates spend time manually scanning LP labels, but the benefit goes beyond labor savings for that one task,” Rapoza says. “The system helps with customer satisfaction and same-day service levels by supporting the need to get the product out the door accurately and on time. The higher we can make our LP accuracy, the more we are going to improve all our downstream processes.”


Running the drones


“The drone missions are run frequently to capture LP images and data from a predefined section of VNA storage at Hillsborough,” explains , operations manager for the site.


There are 34 VNA aisles in total. Each aisle has 26 bays, and each bay has 10 levels of case storage. Typically, one drone mission will scan all the LPs within 10 full bays of one aisle.


Drone flights are usually run during break times or toward the end of a shift when the order picking activity in a section of aisles has ceased or slowed so the aisle can be blocked off with cones and the drone flight can run without worry of interrupting order picking.


One inventory quality control staffer manages each drone mission. A single drone flies autonomously within the aisle once the mission is set up—the associate isn’t working a joystick to fly the unit—but it does require some human oversight to set up and close out a mission. The Hillsborough site keeps two drones on hand, to have one as backup.


Once each drone flight is complete, the Gather AI dashboard highlights any variances against what the mission found, and what ¹û¶³´«Ã½’s WMS says should be in the locations just scanned. In the event there is a variance, it’s investigated and corrected.


Right-sized packaging efficiency


“The CMC system helps us by building boxes around each order to help us reduce the cost of shipping, by having that right-sized carton, while also reducing the manual labor that was previously needed for packing out those orders,” - Rapoza


Another way ¹û¶³´«Ã½ ¹û¶³´«Ã½Centers is bringing targeted efficiencies to its order fulfillment for Stadium Goods at the Hillsborough, N.J., facility is through packaging automation. Specifically, ¹û¶³´«Ã½ deployed an automatic carton packaging system (CMC Packaging Automation) that forms perfectly sized shipping cartons for shoes being fulfilled on behalf of Stadium Goods.


The CMC CartonWrap machine rapidly creates custom shipping cartons from fanfold-fed corrugated cardboard, right-sized to fit around the shoeboxes being shipped to fill single-line orders. The system also automatically applies the shipping label.


Before using the system, packaging single-line orders for Stadium Goods was done using manual pack out stations, with up to 27 stations in use during peak times. Now, except for times of peak order volume, the automation handles the pack out tasks, with 12 pack out stations in reserve for peak times or multi-line orders.


“The CMC system helps us by building boxes around each order to help us reduce the cost of shipping, by having that right-sized carton, while also reducing the manual labor that was previously needed for packing out those orders,” says Rapoza. “There is no direct tie between the drone system and the CMC solution, though ultimately, they are both components of how we are driving down costs while hitting service level agreements through the use of some of these technologies.”


To help reduce the information technology time and effort involved in integrating the right-sized packaging automation system with its WMS, ¹û¶³´«Ã½ used an integration software platform (SVT Robotics). ¹û¶³´«Ã½ also plans to use the platform to simplify the development of full bi-directional integration between its drone inventory monitoring system and its WMS.


The end result is near perfect LP accuracy for the unique cases held in the VNA storage for Stadium Goods. “The LP accuracy is 99.9% or better, so in practice, we know we have every pair of shoes in the building in the right location, so when it’s time to pick, those shoes are right where they are supposed to be,” says Glanzer. “That level of LP accuracy positively impacts everything we need to do downstream, for the pickers, for the packers, and for getting each shipment on the truck at the right time, to meet the end customer’s delivery expectation.”


Glanzer says the drones have proved valuable for tracking LPs on pallets at Hillsborough for other clients, though the drone monitoring holds especially high value for Stadium Goods. “When it is time to pick, the cases are there literally 100% of the time,” he says. “What makes it so effective is that this case inventory is all unique, with its own LP bar code, readable by a drone in the storage medium.”

Sometimes a drone might return a blurred image, but these can usually be zoomed in on enough to read the LP bar code and determine if the case is in the correct location, says Glanzer.


Another lesson ¹û¶³´«Ã½ has learned about the use of drones is that when they are reading LPs on pallets, there should not be excessive pallet overhang, to minimize the risk of a drone striking a pallet. Consistent placement of LP labels helps make the drone system more effective.


¹û¶³´«Ã½ and Gather AI will be working on integration between the drone system’s software and the WMS so variances and count details can flow right into the WMS to simplify the updating of data and creation of any corrective moves. Integration software initially brought on by ¹û¶³´«Ã½ to speed up the integration of a right-sized, packaging automation solution with its WMS (see box, page 24), is expected to help with this integration between the Gather AI system and the WMS.


Targeted efficiency


¹û¶³´«Ã½ is selective in how it leverages the drones, adds Rapoza. For example, it isn’t used in typical forward picking areas where a drone would lack a clear line of sight to bar codes, and for which associates already have system-directed manual scan verification steps in WMS to ensure accuracy. But for very efficiently counting LPs on pallets or cases, especially for fast-moving goods or unique cases, the drones are a labor efficient way to take LP accuracy to the next level.


“Our LP cycle count program with the drones is really focused on what moves, instead of counting product that sits there, like a D-level SKU,” says Rapoza. “For those goods, the drone technology allows us to capture LP data much more efficiently, with much fewer labor hours, and with greater accuracy, than what we could do with a manual counting process. It helps achieve higher quality, at a lower cost.”


Recent Blog Posts

By Katherine Wroth July 16, 2025
When it comes to choosing a third-party logistics (3PL) partner, most companies focus on the obvious: price and technology. Sure, those matter — but they’re just the tip of the iceberg. Bryan Corbett , VP of Sales and Marketing at ¹û¶³´«Ã½ ¹û¶³´«Ã½Centers, has reviewed dozens of RFPs this year from fast-growing DTC startups to Fortune 100 companies. And time after time, he’s seen three often-overlooked factors that can make or break a 3PL relationship. Here are the top three things Bryan says every brand should consider when selecting a 3PL: 1. Choose a 3PL You Can Grow With This is the big one. Don’t pick a 3PL based solely on what your business needs today. Pick a partner that can scale with you in a year, three years, or even five years down the road. The most successful brands think ahead and ask: Who can help us reach our future state? Who has the infrastructure, people and mindset to evolve with us? It’s easy to treat a 3PL search like checking a box—but if you do that, you risk locking into a provider that can’t support your growth. Look for a strategic partner, not just a service provider. If growth isn’t part of your roadmap, you might want to revisit your goals altogether. 2. People Matter—A Lot You grow with people, not platforms. The team behind your 3PL will become an extension of your business, so you need to feel confident they’d fit right in on your own org chart. Ask yourself during the RFP process: Can I picture these people working at our company? Do they “get” our brand and how we operate? At ¹û¶³´«Ã½, we always say we’re only as strong as the GMs and ops leaders inside our buildings. That’s why we encourage prospective partners to go beyond sales conversations. Meet the actual people running the floor. Build relationships with the folks you’ll be emailing and calling when it matters most. 3. Don’t Underestimate Culture Fit If the first two points are about future potential and strong people, culture is the glue that holds it all together. Alignment on work ethic, speed of execution and communication styles plays a huge role in long-term success. When things go wrong—and at some point, they will—you want to be aligned on how to solve problems and how quickly you move. We’ve seen deals fall apart not because of cost or capabilities, but because of mismatched cultures. On the flip side, when we meet a brand that feels like a natural fit for ¹û¶³´«Ã½, we know the partnership will thrive. Final Thought Price and tech are table stakes. But if you want a long-term, high-impact 3PL partnership, look deeper. Ask these three questions: Can this partner grow with us? Do they have the right people in place? Are we aligned culturally? When those answers are yes, you’ll set your supply chain—and your business—up for real success. Have questions about finding the right 3PL fit? Contact us to schedule a complimentary supply chain consultation today.
By Katherine Wroth July 11, 2025
FRANKLIN, Mass., July 14, 2025 /PRNewswire/ -- Profoto , the global leader in light-shaping technology for imaging professionals, has selected ¹û¶³´«Ã½ ¹û¶³´«Ã½Centers as its third-party logistics (3PL) provider in the United States. Operations are now live at one of ¹û¶³´«Ã½'s facilities in Somerset, N.J. As premium brands face increased pressure to deliver faster and more reliably, Profoto's partnership with ¹û¶³´«Ã½ reflects the growing need for logistics providers that can move quickly without sacrificing quality. "We ran a competitive RFP process, led by our global partner, Establish Inc. , and ¹û¶³´«Ã½ quickly rose to the top," said Daniella Stolpe , business operations and IT manager at Profoto. "Their location near our key customer in New York, strong systems and analytics, and attention to detail really impressed us. Most of all, it was the people. ¹û¶³´«Ã½ was responsive, thorough and truly invested in building a long-term partnership." ¹û¶³´«Ã½'s solution includes receiving ocean and airfreight shipments, cycle-count inventory management, secure pick-and-pack services for fragile goods, returns processing, parcel and LTL transportation management and supply procurement. "Profoto faced a sudden non-renewal from its previous 3PL, creating an urgent need for a smooth transition," said Sally Caputo , head of 3PL services at Establish. "¹û¶³´«Ã½ delivered an on-time go-live with API integration, real-time visibility and improved shipping rates. We've placed other clients with them and continue to see the high-level service we expect." To meet the tight timeline, ¹û¶³´«Ã½'s engineering and IT teams designed a flexible warehouse layout and completed a fast-tracked integration aligned with Profoto's ERP migration. "Profoto needed a partner who could move fast and scale with their growth," said Scott Wilkins , vice president of customer solutions at ¹û¶³´«Ã½. "Our team delivered on time and collaborated seamlessly. We're proud to support their U.S. expansion." The partnership highlights how ¹û¶³´«Ã½ meets high-performance brands' complex supply chain needs through personalized solutions, real-time visibility and scalable operations. About Profoto Founded in 1968 and headquartered in Sweden, Profoto is the world's leading manufacturer of photography lighting equipment, trusted by the best photographers in the industry, especially in fashion. With presence in nearly 50 countries and subsidiaries in New York, Tokyo, Hamburg, Paris, London and Scandinavia, Profoto sets the standard for innovation and quality. Combining a legacy of photographic excellence with a dynamic, disciplined culture, Profoto delivers premium lighting solutions that shape the future of professional image creation. About ¹û¶³´«Ã½ ¹û¶³´«Ã½Centers Since 1941, ¹û¶³´«Ã½ has provided customized third-party logistics (3PL), direct-to-consumer (DTC) eCommerce fulfillment, omnichannel distribution, managed transportation solutions and retail compliance for clients across all industries, with a focus on apparel & footwear, health & beauty, consumer packaged goods (CPG) and education. ¹û¶³´«Ã½ continues to be a leading 3rd party logistics provider in North America, known for superior execution, customer engagement and direct access to senior leadership decision makers. As a member of Inc's fastest growing companies list 15+ times, ¹û¶³´«Ã½ is big enough to do the job and still small enough to deeply care about your business. Brands interested in a new 3PL partnership may contact ¹û¶³´«Ã½ directly here . About Establish Inc. Establish is a supply chain consulting firm offering specialized services in the optimization of the supply chain. With over 50 years of experience and thousands of projects under their belts, Establish has been trusted by some of the largest and best-known corporations in North America and Europe as well as smaller companies. Establish's lasting success is attributed to their team of the sharpest mathematicians and analysts; armed with the state-of-the-art tools. The delivery of both quantitative analytics and strategic insights makes Establish uniquely qualified to service their clients most pressing supply chain needs. Establish approaches each engagement ensuring recommendations are actionable and sustainable, even leading the implementation of new initiatives through steady state.  Official Release Here
By Katherine Wroth July 8, 2025
Teaneck, NJ – June 20, 2025 – Made4net, a global provider of cloud-based Warehouse Management Systems (WMS) and end-to-end supply chain execution software , proudly presented the first-ever Made4net Award for Advancing Innovation in Third-Party Logistics at the 2025 IWLA Convention & Expo, held May 4–6 in Tucson, Arizona. This new award honors an IWLA member company demonstrating exceptional vision, leadership, and commitment to driving innovation in the 3PL space. ¹û¶³´«Ã½ ¹û¶³´«Ã½ was named the inaugural recipient of the award for its forward-thinking approach to logistics operations and ongoing investments in transformative technologies. One standout example is ¹û¶³´«Ã½’s use of Gather AI’s advanced drone-based inventory technology at its Hillsborough, N.J. facility. This technology helps reduce manual labor and cycle counting time while increasing inventory accuracy and fulfillment speed. The system works alongside Made4net’s Synapse 3PLExpert WMS , supporting ¹û¶³´«Ã½’s mission to create a more intelligent, efficient, and responsive warehouse environment. “Third-party logistics providers are the backbone of so many supply chains, but their contributions often go unrecognized,” said Chipper Farley, President of 3PL Solutions at Made4net and newly appointed IWLA Board Member. “We launched this award to spotlight 3PL leaders who aren’t just responding to change—they’re shaping what’s next. ¹û¶³´«Ã½ Distribution’s bold and effective use of emerging technology is a perfect example of the innovation we want to celebrate.” With over 80 years of experience, ¹û¶³´«Ã½ continues to raise the bar in the 3PL industry by embracing digital transformation and championing operational excellence. “We’re honored to be recognized by Made4net and IWLA for our efforts to lead through innovation,” said Douglas Varga, Vice President of Information Technology at ¹û¶³´«Ã½ Distribution. “This award reflects the work our team has done to evaluate, adopt, and scale technology that enhances the service we deliver to our customers.” The Made4net Award for Advancing Innovation in Third-Party Logistics will be awarded annually at the IWLA Convention & Expo to spotlight the achievements of IWLA members who demonstrate a commitment to innovation and leadership in the evolving world of logistics. About ¹û¶³´«Ã½ ¹û¶³´«Ã½ ¹û¶³´«Ã½ ¹û¶³´«Ã½currently operates 25+ facilities across the United States. With over 6 million square feet of space specifically designed for warehousing, distribution, transportation and omnichannel eCommerce fulfillment, ¹û¶³´«Ã½ will scale your brand to ensure success. Learn more at www.barrettdistribution.com . About IWLA IWLA, formerly the American Warehouse Association, serves nearly 600 corporate members representing 3,000 warehousing locations. Since 1891, the organization has been the resource for warehouse logistics, advocacy, and education. For more information, visit www.IWLA.com . About Made4net Made4net is a leading global provider of best-in-class, cloud-based supply chain execution and warehouse management solutions for organizations of all sizes to improve the speed and efficiency of their supply chain. Full Release Here: https://made4net.com/made4net-presents-inaugural-award-for-advancing-innovation-in-third-party-logistics-at-2025-iwla-convention-expo/
More Posts