Automation is shaping every industry, especially supply chains and warehousing. But what happens when your warehouse is nearly three decades old? Can legacy infrastructure be transformed with innovative technology? That was the challenge faced by TD SYNNEX, a global distributor of technological equipment. Together with WDP, the company set out to modernize its operations by expanding its existing warehouse with a new automated facility. 

To efficiently manage this wide product mix, the warehouse is organized into different operational zones. Some products, such as printers, can be shipped in their original packaging, while others (e.g. smartphones, cables, and USB sticks) require additional handling and repackaging before dispatch. This operational complexity highlighted the need for automation, particularly in the repack processes, to improve efficiency and streamline workflows. 

Before focusing on specific technologies, TD SYNNEX needed to determine whether automation could be integrated into its existing warehouse or whether a completely new facility would be required. ​“In nearly three decades, very little had changed in our existing warehouse. But we began to feel that we were reaching the limits of our storage capacity. That led us to a key question: should we relocate, or can we expand?”, says Brecht Van Hulle, Sr. Logistics Director Benelux at TD SYNNEX. 

“In the summer of 2020, a joint assessment with our partner WDP showed that we would need 15% more space, or approximately 3,000 square meters, to support sustainable growth over the next 10 to 15 years. That is why we chose to expand our warehouse and increase storage capacity through the integration of automated solutions.” 

TD SYNNEX’s warehouse in Aalst proved to be an ideal candidate for brownfield automation – the process of retrofitting existing facilities with modern automation technologies. In fact, the Belgian site became a pilot project for other TD SYNNEX warehouses across Europe. ​“Before automating additional facilities, we needed to verify whether our automation plans would deliver the expected gains in productivity and efficiency”, says Van Hulle. ​“If it works here, we can apply those learnings to other warehouses that could benefit from similar solutions. From storage and picking to packaging, our site has effectively become a test case for future implementations.” 

The new hall is equipped with a shuttle system, goods-to-person solutions, automated box creation, and a high-capacity sorter handling 7,000 SKUs. The system can store up to 12,000 totes and significantly improves storage density and operational productivity. Implementing this project came with several challenges. From an infrastructure perspective, ceiling heights and the positioning of conveyors required close collaboration with architects and partners such as WDP. Integrating automation also demanded extensive testing and staff training. 

Meanwhile, the existing warehouse operations had to remain fully functional throughout the project. ​“One of the main challenges was the noise during construction and implementation, particularly given our proximity to a residential area. Maintaining open communication with employees and residents was key to minimizing disruption and ensuring continued operations throughout the project”, explains Brecht Van Hulle. 

This brings us to another key factor in automation: people. While the technology is not intended to replace jobs, it does change the way people work. Many employees fear they will be replaced by robots, but the opposite is true. ​“For TD SYNNEX, automation means creating job security for the next two decades”, says Van Hulle. ​“But you need to explain to people why you are doing this and how it fits into your long-term vision. That’s why we involved as many stakeholders as possible early in the process. They may provide valuable insights and uncover considerations you hadn’t anticipated. It also helped us identify competencies we needed to strengthen our team.” 

For TD SYNNEX, automation has delivered a significant productivity boost. ​“Previously, our team handled around 50 manual picks per person per hour. Today, with the support of automation, they can achieve up to 350 picks per hour. We also integrated the automated and manual sections of the warehouse, which allows us to use 200 fewer boxes each day. This creates both economic and environmental value for the customer”, explains Van Hulle. ​“Additionally, the new hall has created more capacity for incoming and outgoing goods, with space for 2,000 extra pallets.” 

TD SYNNEX’s warehouse in Aalst has become a benchmark for other automation projects in Europe. ​“We are proud to have achieved this in Belgium rather than in one of our warehouses in larger countries. What also helped was the experience and seniority of our team in Aalst. Their expertise was instrumental in ensuring the system was implemented efficiently, while our existing operations continued to run smoothly throughout the entire process”, says Van Hulle. 

In addition to this internal expertise, TD SYNNEX also collaborated with experienced partners such as WDP. ​“This is not the kind of project you can deliver on your own. You need partners you can trust and with whom you can build a strong relationship. That’s why I highly valued the open communication we had with WDP. They truly supported us and helped make this a very positive project experience.” 

What advice can Brecht Van Hulle give to other companies considering warehouse automation? ​“First of all, think carefully before you start. I was not immediately in favor of automation, so we challenged every assumption. Don’t automate for the sake of automation. It is also important to visit companies that have already successfully implemented automated solutions, so you can see the technology in action. Be aware that you will make mistakes along the way but keep moving forward. It could also be a good idea to appoint a dedicated project manager for the initiative. And finally, rather than working with different partners for every part of the project, choose consultants and suppliers you can trust and rely on throughout the entire process.” 

Ultimately, TD SYNNEX is pleased to have chosen brownfield automation over building a new warehouse. ​“If you relocate to a different site, you risk losing your team. Their knowledge and experience are irreplaceable. Secondly, you know your warehouse inside out. We were already one of the most productive TD SYNNEX facilities in Europe, and now we are growing even further. When something works well, you want to preserve it and continue building on it. I’m convinced that almost every warehouse can benefit from an upgrade, but it requires strong coordination and a solid plan. For us, brownfield automation has been a real success”, concludes Van Hulle. 

About TD SYNNEX

TD SYNNEX is the world’s largest distributor of IT-related technology products, services, and solutions. For over 40 years in over 100 countries, they have provided logistics capacity, capabilities, and added value that support distributors and partners as efficiently as possible when it comes to end-user technology demands.

TD SYNNEX has a specific vision for a dynamic, interconnected world. They believe everyone can do great things with technology. Through their vision and values of inclusion, partnership, integrity, and their desire to excel, they have a rich history of strong business results, local focus, and resources together with their distributors, partners, and vendors. TD SYNNEX listens to what employees, clients, vendors, and investors really need to be successful.