Warehouse Transformation: Case Study

Next PLC, one of the UK’s leading fashion and homeware retailers, faced increasing challenges in meeting growing e-commerce demand in a highly competitive and fast-changing industry. With high order volumes and customer expectations for rapid delivery, Next sought to improve operational efficiency by scaling up their Yorkshire fulfillment centre.

The goal of this project was to create additional floor space within an existing warehouse to accommodate robotic automation, which would be used by Next to enhance their goods-to-person picking and sorting processes to achieve faster, more efficient operations.

Project Scope & Objectives

To meet the growing demands of the company and streamline operations, Next required a significant expansion of their Dearne Valley Pallet facility near Rotherham. The project’s primary aim was to create 22,000 square meters of additional floor space and integrate robotic automation systems to improve efficiency in picking and packing goods.

The scope of the project involved two key areas:

1. Mezzanine Floor Extension

Installation of a 22,000 square metre mezzanine extension atop an existing two-tier structure, requiring substantial reinforcement and the use of over 1,500 tonnes of steelwork and decking.

 

2. Automation Integration

Supporting Next’s hybrid pick-and-sort solution, which combined AMRs (Autonomous Mobile Robots) from Geek+, automated conveyors from JBT, and pallet shuttles from Savoye, to enable efficient goods-to-person picking and sorting processes.

Challenges Faced

The project posed several challenges, requiring meticulous planning and coordination to ensure successful completion while maintaining warehouse operations.

Operational Constraints

The warehouse needed to remain fully operational throughout the project, with up to 500 Next employees continuing their daily tasks. This meant that the logistics and scheduling of the project needed to be managed carefully in order to avoid disruption and maintain productivity.

 

Structural Challenges

Building on an existing two-tier mezzanine presented structural challenges; in particular the need for reinforcement to support additional load.

Connecting the new mezzanine to the existing framework required meticulous planning, precision engineering, and specialised equipment. Spatial constraints added complexity, as materials and equipment had to be maneuvered carefully in tight spaces.

 

Coordination with Multiple Stakeholders

Collaboration with a large number of subcontractors and technology partners was critical to ensure that:

 

1. The project was compliant, completed on time and carried out without causing disruption.

2. Physical infrastructure was fully compatible with the robotic systems that would be introduced to the facility.

 

The integration of automation systems from multiple vendors added another layer of complexity to the project. This all meant that aligning timelines, deliveries and technical requirements required robust project management to avoid delays and miscommunication.

Solution Delivered

Effective project management is at the heart of our turnkey service, ensuring every step of a warehouse automation project is perfectly executed. By overseeing each stage as part of a detailed and fully coordinated plan, our aims are simple; to provide the best solutions while reducing complexity, maintaining efficiency, and delivering results on time and within budget.

Access & Logistics

 

To facilitate efficient material handling and negate disruption inside the facility, a temporary access point was created on the warehouse’s exterior. This involved creating an opening at the height of the second floor to streamline the delivery of steel and decking materials.

 

Avanta also managed precise coordination of the logistics involved in the project to ensure the continuous movement of materials while maintaining safety and avoiding operational delays. A carefully planned day/night shift strategy ensured minimal disruption to the warehouse’s ongoing operations. Day shifts focused on loading materials, while night shifts carried out construction work to maintain consistent progress.

Design & Construction

Expanding the mezzanine required extensive structural reinforcement to ensure stability and durability. As the principal contractor, Avanta UK oversaw the full Construction, Design, and Management (CDM) process, ensuring the project met all safety, regulatory, and operational standards.

Key solutions included:

Use of Specialised Equipment

Scaffolding and spider cranes allowed for the transport and installation of over 1,500 tonnes of steelwork and double-boarded timber decking, even in confined spaces.

Reinforced load-bearing columns

Bracing and additional steel supports distributed weight evenly across the structure.

Connection to existing steelwork

Custom-fabricated components seamlessly integrated new and old frameworks for enhanced structural integrity.

Fully Configured Mezzanine

With the structural elements in place, all necessary components of the mezzanine floor were installed including:

 

• Fully double boarded decking

 

• Five staircases including connection to existing access points

 

• Chutes from the mezzanine to lower packing stations

 

• Elevators to lower levels

 

• Mesh safety fencing

 

ROBOTFLOOR Installation

‍ROBOTFLOOR, a 3mm heavy-duty resin floor coating was applied to prevent static build up and optimise the performance of robotic systems. The durable surface provided smooth navigation for AMRs and AGVs, ensuring long-term reliability in high-traffic areas.

‍Environmental Systems

‍Advanced air handling systems were installed to regulate temperature and airflow, ensuring a comfortable environment for both employees and robots.

The project’s success relied on seamless collaboration between all stakeholders. Avanta worked closely with the client as well as designers and architects, subcontractors and automation providers to refine the design, execute the plan and manage the entire process with precision.

 

Key responsibilities included:

 

• Undertaking Principal Contractor duties and managing all subcontractors on behalf of the client.

 

• Ensuring compliance with all building control regulations.

 

• Implementing fire-engineered solutions to meet safety standards.

 

• Conducting regular safety audits to maintain a secure construction environment throughout the project.

Technological Integration

The successful integration of robotic systems with the necessary supporting infrastructure was critical to transforming Next’s Yorkshire fulfilment center into a high-efficiency, automated facility. This combination of additional space, compatible storage and advanced robotics meant that the facility was designed to handle increasing volumes of goods with precision and scalability.

Robots Involved

The project centered on a hybrid Pick-and-Sort solution that incorporated two primary types of robots from automation provider Geek+:

‍P800 AMRs (Autonomous Mobile Robots)Fifty six P800 robots were introduced to handle the retrieval and transportation of racks within the warehouse, navigating using QR code-based systems. The P800s bring racks to multifunctional workstations, enabling efficient goods-to-person picking.

 

‍S20T Sorting Robots

‍Fifty individually numbered S20 robots were deployed to transfer picked items to designated chutes, streamlining the sorting process and ensuring seamless delivery to packing stations below.

Together these robotic systems enabled Next to process up to 16,000 units per day, doubling the efficiency of manual picking. The QR code-based navigation ensured precise movements, reducing delays and errors.

 

Storage & Racking Systems

To support the robotic operations, tailored racking and storage systems were installed including 600 bays of warehouse shelving. These solutions were carefully configured to optimise storage density while ensuring compatibility with the AMRs. Key considerations included:

• Rack Design: The racking layout was configured to facilitate smooth robotic access, with sufficient clearance for AMRs to retrieve and transport racks without disruption.

• Structural Stability: The systems were integrated into the reinforced mezzanine structure to provide long-term durability and support the increased storage capacity.

• Scalability: The modular design allows for future expansion when Next needs to scale up its operations.

The integration of racking and shelving with carefully positioned equipment such as chutes and packing stations ensured that storage, robotic and manual operations were fully aligned. This joined up approach was designed to achieve not only maximum storage efficiency, but also to ensure maximum efficiency from the automated system.

We hold comprehensive insurance policies and are SafeContractor, CHAS and Constructionline accredited, as well as being ISO9001:2015 certified so you can be sure that your project will be managed safely and effectively.

 

Safety Features

Robotic containment was ensured through removable mesh safety guarding, while modifications to mesh safety fencing supports smooth robot operations, protects personnel and maintains safety compliance.

Fire protection measures for the project included fire rated chute enclosures and fire rated staircase enclosures between levels.

Results and Outcomes

 

Efficiency Gains

Next achieved double the efficiency of manual picking, with the upgraded facility able to handle up to 16,000 units per day. The new automation system enabled Next to manage record volumes of customer orders during the Christmas season without additional labour.

Since the project was completed, Next was also able to extend their next-day delivery cutoff from 6 pm to 10 pm. Ultimately the project has enabled Next to successfully meet growth in customer demand and significantly improve operational efficiency, all while delivering a better customer experience.

 

Time and Cost Savings

The project was completed 14 weeks ahead of schedule, thanks to efficient planning and execution. As well as being more productive, the facility is now able to operate more cost effectively and is well prepared for future growth, with the ability to scale up operations as needed.

 

No Downtime

Due to the way in which the new mezzanine level was installed, the facility was able to remain fully operational throughout the project. This enabled Next to avoid what otherwise would have been significant costs and disruption to their business.

 

Future-Proofing

The additional mezzanine space and integration of modular storage solutions provide Next with the flexibility to adapt to changing business needs. The ROBOTFLOOR coating and mezzanine construction ensure the facility can support new technologies and growing automation demands without major infrastructure changes.

 

Scalable Operations

The design of the floor space, storage and automated systems enables Next to scale up efficiently by adding more robots into the facility if needed.

Expertise In Preparing For Automation

Next PLC’s Yorkshire fulfillment centre has been transformed into a high-performance facility capable of meeting today’s e-commerce challenges while remaining adaptable for future demands. Avanta UK’s role as the principal contractor ensured that the project was delivered without disruption, on budget, ahead of  schedule and fully prepared for the seamless integration of advanced robotic systems.

The collaboration between Avanta UK and automation providers has positioned Next at the forefront of warehouse automation, ensuring the business is fully equipped to manage future growth and challenges.

Avanta works with businesses of all sizes to implement scalable, robot-ready warehouse solutions. Our expertise means our clients can be confident the entire project will be handled efficiently and professionally from start to finish, without them needing to manage multiple subcontractors, ensure compliance or worry about installation challenges.

To find out more about how we can transform your warehouse or workspace and help you meet your objectives, get in touch with our team.

 

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