Cutter & Buck is expanding its North American distribution capabilities with the opening of a second automated distribution center in Grand Prairie, Texas. The apparel company inaugurated the facility last week, building on its existing automation partnership with Kardex and its experience operating AutoStore technology, according to a press release.
The new site is the company’s second warehouse to use AutoStore’s goods-to-person technology, which brings stored items to employees rather than requiring them to retrieve products manually across the warehouse. The system is designed to handle 1,256 storage bins per hour, while simulations conducted with AutoStore exceeded that target, reaching an average of 1,284 bins per hour.
The installation comprises 50,502 storage bins, 32 AutoStore R5 Pro robots and 13 ports. Its modular design also allows Cutter & Buck to add robots and ports as order volumes and operational requirements evolve.
Kardex, which specializes in automation and material handling systems, integrated the technology into the Grand Prairie operation. Its warehouse software coordinates AutoStore activities, while a dedicated conveyor network connects the automated storage system to subsequent fulfillment stages.
These processes include embroidery, routing, printing and labeling, as well as shipping. By connecting the different stages of order preparation, the system is intended to improve the handling of both undecorated and customized apparel orders while supporting the broader requirements of the company’s distribution operations.
A facility built for future growth
The Grand Prairie distribution center was designed to accommodate up to 10 million units of apparel, footwear and accessories. It will also support rapid embroidery services, giving Cutter & Buck additional capacity to manage its product range and customization requirements.
According to an April announcement from the City of Grand Prairie, the project is expected to bring 150 jobs to the area. Texas is currently the company’s largest sales market, making the state an important location for strengthening its fulfillment infrastructure.
Rather than simply duplicating its existing automated warehouse in Renton, Washington, Cutter & Buck used the lessons learned from that operation to shape the design of its new Texas facility.
“Our experience in Renton gave us a clear understanding of what automation can make possible for our operation and our customers,” Cutter & Buck CEO Joel Freet said. “With Kardex, we’ve been able to take what we’ve learned and apply it to a new facility designed around where our business is going next.”
Building on the Renton automation project
Cutter & Buck first introduced AutoStore technology at its Renton distribution center in 2023. The original installation included more than 34,000 storage bins and 54 robots. Its primary objectives were to maximize storage capacity within the existing building, improve operational efficiency and order accuracy, increase throughput, and reduce reliance on seasonal workers.
As demand increased and the company expanded its stock-keeping unit (SKU) assortment, the Renton system was subsequently scaled up. According to the October announcement, the expansion added another 9,962 storage bins, together with additional ports and supporting infrastructure.
That experience provided the operational foundation for the Grand Prairie project. Having already worked with AutoStore for several years, Cutter & Buck was able to identify which elements of the original installation delivered the greatest benefits and where adjustments could better support its future needs.
Scott Sumpter, executive director of distribution, enhancement and logistics at Cutter & Buck, highlighted the value of that experience in a statement.
“We had years of experience operating AutoStore in Renton, WA, and a much better understanding of how the system supports our people, our processes, and our customers,” Sumpter said. “That experience allowed us to work with Kardex to take what we had learned, build on what worked, and design the Texas facility around what we’ll need as the business continues to grow.”
With its second AutoStore-powered distribution center, Cutter & Buck is applying an established automation model to a new facility designed around its projected business needs. The combination of high-density storage, robotic handling and integrated downstream processing is intended to give the apparel company greater flexibility as order volumes, product variety and customization requirements continue to develop.
