CASE STUDIES
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Case Study 1: Automating Mezzanines with Omni Rack Robotics
How a major apparel retailer automated a 4-level mezzanine without floor prep, rack replacement, or operational downtime.
The Challenge
An apparel retailer running both B2C and B2B fulfillment needed to automate a complex pick module spanning four mezzanine levels with ceilings as low as 8 feet. The mandate: no new construction, minimal disruption, and a proof-of-concept that could scale over time.
They wanted to:
● Use the existing racking and infrastructure
● Avoid the need for extensive permits
● Start small and expand over 18 months
● Minimize labor costs while increasing throughput
● Avoid the need for extensive permits
● Start small and expand over 18 months
● Minimize labor costs while increasing throughput
The Solution
Cartesian Kinetics’ Carte+, the world’s first Omni Rack Robotics (ORR) system, was considered the ideal choice for a mezzanine deployment. ORR refers to robotic systems that can be retrofitted onto any racking structure—standard or mezzanine—without structural changes. Carte+ installs quickly, requires no floor prep, and adapts to constraints like low ceilings and narrow aisles. The modular hardware and reconfigurable software architecture enables a smooth install and flexible scaling.
Key Differentiators
● Installs on existing racking—standard or mezzanine
● Works with ceilings as low as 8 feet
● No floor traffic and no floor prep
● Modular and scalable: one aisle at a time
● Software reconfigurable for seasonal or SKU changes
● Works with ceilings as low as 8 feet
● No floor traffic and no floor prep
● Modular and scalable: one aisle at a time
● Software reconfigurable for seasonal or SKU changes
Project Metrics
● Mezzanine Height: 8 ft
● SKUs: 2,100
● Robots: 16
● System Footprint: 4,410 sq ft
● Throughput: 1,100 units/hour
● Operators Required: 1 per shift (non-peak), 2 during peak
● Picking Mode: Automated Batch Picking
● Integration: Live WMS order streaming
● SKUs: 2,100
● Robots: 16
● System Footprint: 4,410 sq ft
● Throughput: 1,100 units/hour
● Operators Required: 1 per shift (non-peak), 2 during peak
● Picking Mode: Automated Batch Picking
● Integration: Live WMS order streaming
Results
● Manual Labor Reduction: 85%
● Projected Cost Savings: 65% annually
● ROI Achieved in: 1.5 years
● Projected Cost Savings: 65% annually
● ROI Achieved in: 1.5 years
Why It Matters
This project shows how Carte+ can unlock automation in brownfield environments that traditional systems can’t touch. Mezzanines, low ceilings, and space constraints are no longer barriers. With Cartesian Kinetics’ Carte+, automation starts where your racks already stand.
Case Study 2: Turning Unusable High Bays into Fulfillment Assets
How Carte+ revived five aisles of dead space—without new infrastructure or expensive cranes
The Challenge
An apparel manufacturer faced a classic automation dilemma: five aisles of high-bay racking were inaccessible due to obsolete crane systems. New automation options would have required a full rip-and-replace—costing over $18M and months of downtime.
The Solution
Rather than rebuild, the facility had the option to retrofit. Carte+ could be installed directly onto existing high-bay racks—no structural upgrades, no permitting delays, and seamless integration with the client’s WES. Developed by Cartesian Kinetics, this Omni Rack Robotics solution is designed to restore access to thousands of totes at high speed, with minimal labor requirements.
Project Metrics
● Ceiling Height: 42 ft
● Totes: 11,000
● Robots: 6
● Cases per Hour: 250
● Operators: 1 per shift
● Footprint: 3,250 sq ft
● Process: Automated on-demand case retrieval
● Integration: Tote requests from WES
● Totes: 11,000
● Robots: 6
● Cases per Hour: 250
● Operators: 1 per shift
● Footprint: 3,250 sq ft
● Process: Automated on-demand case retrieval
● Integration: Tote requests from WES
Business Impact
● 11,000 SKUs recovered from previously inaccessible shelving
● Full ROI projected in < 3 years
● Minimal labor and no new infrastructure
● Full ROI projected in < 3 years
● Minimal labor and no new infrastructure
Why It Matters
With Omni Rack Robotics, companies can reclaim high-bay shelving previously considered off-limits. Carte+ shows that automation doesn’t require rebuilding—just rethinking. That’s the power of Cartesian Kinetics.
Case Study 3: High Throughput for a Multi-Tenant 3PL
How Carte+ helped a 3PL scale fast-pick fulfillment across four clients—without floor prep or complexity
The Challenge
A growing 3PL needed a smarter way to handle ecommerce fulfillment across multiple tenants. They wanted to unify batch and order picking in one system, flex for peak demand, and potentially relocate the system in the future.
The Solution
Carte+ suggested a deployment in a modular setup that retrofitted into existing racking—no floor prep required. The system, designed by Cartesian Kinetics, can allow each tenant’s workflow to run independently while optimizing for shared labor and robotic efficiency. As an Omni Rack Robotics solution, it brings structure without rigidity.
Project Metrics
● Ceiling Height: 42 ft
● Totes: 600 partitioned
● Robots: 10
● Footprint: 750 sq ft
● Operators: 2 per shift
● Throughput: 6,000 picks per shift
● Process: Automated order and batch picking
● Integration: Order batch/streaming from WMS
● Totes: 600 partitioned
● Robots: 10
● Footprint: 750 sq ft
● Operators: 2 per shift
● Throughput: 6,000 picks per shift
● Process: Automated order and batch picking
● Integration: Order batch/streaming from WMS
Business Impact
● 5–7X productivity improvement
● 57% reduction in manual labor
● ROI achieved in ~2.5 years
● Easily relocatable and reconfigurable
● 57% reduction in manual labor
● ROI achieved in ~2.5 years
● Easily relocatable and reconfigurable
Why It Matters
Multi-tenant operations demand flexibility. Omni Rack Robotics gives 3PLs the infrastructure to scale and shift without constraints. Carte+ from Cartesian Kinetics meets modern needs without adding complexity.
Case Study 4: Scaling Distribution with Simple Automation
How Carte+ gave a grocery distributor the ability to grow without adding labor
The Challenge
A grocery distributor planned to launch a D2C channel, but had limited automation, rising labor costs, and no spare headcount. With 800 SKUs and variable demand, their manual process couldn’t scale.
The Solution
Carte+ could be configured as a standalone system optimized for high-velocity SKUs and real-time order profiles. In this case, Carte+ was designed to handle fulfillment with just two robots, one operator, and minimal IT requirements.
Project Metrics
● Ceiling Height: 42 ft
● SKUs: 800
● Totes: 200
● Robots: 2
● Footprint: 500 sq ft
● Operators: 1 per shift
● Throughput: 300 units/hour
● Process: D2C and store replenishment picking
● Integration: Standalone / CSV-based
● SKUs: 800
● Totes: 200
● Robots: 2
● Footprint: 500 sq ft
● Operators: 1 per shift
● Throughput: 300 units/hour
● Process: D2C and store replenishment picking
● Integration: Standalone / CSV-based
Business Impact
● 4X productivity boost
● 80% error reduction
● No new labor added
● Automated picking in weeks, not months
● 80% error reduction
● No new labor added
● Automated picking in weeks, not months
Why It Matters
Facilities without full-scale IT or traditional automation infrastructure can still modernize. Carte+—an Omni Rack Robotics system from Cartesian Kinetics—makes growth possible without growing your headcount.