As e-commerce demand accelerates and product portfolios become more complex, fulfillment operations need to scale without sacrificing speed, accuracy, or customer satisfaction. For Scentsy, a 160,000-square-foot fulfillment center originally designed around manual operations was reaching the limits of its existing model. Manual picking was capped at 300 units per hour, seasonal demand created bottlenecks, and growing SKU volumes placed additional pressure on storage capacity.
This case study from Dematic explains how Scentsy transformed its fulfillment operation through automation, combining AutoStore™, intelligent software, and batch picking into a scalable fulfillment architecture. The result was nearly 50% more picking capacity and a system designed to support future growth.
Rather than adding labor to address growing order volumes, Scentsy worked with Dematic to create a modular system that improved storage density, picking efficiency, inventory visibility, and operational flexibility.
You will learn:
• How Scentsy moved from manual fulfillment to an automated operating model
• Why AutoStore helped increase storage density and accommodate more SKUs
• How 100 R5 robots manage 20,800 storage bins
• How batch picking enables 10 to 40 orders to be processed in a single pass
• How Dematic Software coordinates inventory, tasks, and order batching in real time
• Why integration with existing WMS and ERP systems improves operational visibility
• How digital workflows eliminate paper tickets and reduce manual errors
• How modular automation supports future expansion and seasonal demand
• Why lifecycle services and 24/7 support are important for long-term system performance
The solution combines AutoStore with Dematic Software and a pick-to-cart system. AutoStore’s modular grid uses 100 R5 robots to manage 20,800 bins, delivering products to 16 carousel ports and two conveyor ports. The architecture maximizes available space while supporting future expansion and energy-efficient operation.
The pick-to-cart workflow further increases productivity by allowing operators to process multiple orders simultaneously. Dematic Software groups orders into optimized waves and guides operators through digital instructions, allowing up to 18 active orders to be handled at once.
The results were measurable. In just 18 months, Scentsy transitioned from manual picking to an automated fulfillment system, increasing picking capacity by nearly 50% without reducing headcount. Employees moved into higher-value roles, paper tickets were eliminated, and the modular system created a foundation for continued expansion and predictive analytics.
This case study is designed for fulfillment leaders, warehouse executives, e-commerce operations teams, supply chain professionals, logistics managers, and businesses evaluating warehouse automation for growing order volumes.
Download Scalable Fulfillment: How Scentsy Transformed Operations with Dematic to learn how automated storage, intelligent software, and batch picking can increase fulfillment capacity while creating a scalable foundation for long-term e-commerce growth.
