At its West Auckland campus, Douglas, one of New Zealand’s largest family-owned healthcare business, has installed New Zealand’s first AutoStore TM system to future-proof its fulfilment operations. Delivered in partnership with Kardex, the system supports domestic orders across retail, wholesale and direct-to-consumer channels.
Douglas faced a familiar challenge. Its 1,800 sq m warehouse was nearing capacity. Growth was strong, but space was limited.
Three options were considered:
– Expand the existing warehouse
– Purchase a second site
– Invest in high-density automation
Expansion would have been costly and disruptive. A second site introduced complexity. Automation offered a scalable alternative.
Clear, Measurable Results
The installed system includes:
– 6,300+ storage bins
– 13 robots
– 4 Ports
Uses just 10% of the warehouse footprint
The operational impact has been immediate:
– 68% improvement in operational throughput
– Picking increased from 50 to 200 order lines per hour
– 99.99% pick accuracy
– 25% faster order cycle time
– 30% more storage capacity within the same building
– 3,000 order lines processed daily, 92% via automation
For Douglas, this means growth without relocation and without expanding its building footprint.
It also improves working conditions. Robots handle product movement. Staff pick at ergonomic stations. Accuracy and traceability are strengthened, critical for healthcare operations.
Managing Director Jeff Douglas described the investment as essential to supporting long-term expansion while improving efficiency and reducing waste.
A Growing Automation Footprint in New Zealand
Douglas is part of a broader trend.
On 20 March, NZ Safety Blackwoods will officially open its new automated fulfilment facility in Drury, reinforcing the shift towards scalable infrastructure across the industrial and safety supply sector.
This reflects its strategic investment in scalable infrastructure to support customers across New Zealand.
These projects signal a maturing automation market. Manufacturing, healthcare and industrial distributors are choosing systems that:
– Increase storage density by up to 400% within existing space
– Deliver 99.8% uptime
– Scale by adding robots and bins without operational shutdown
– Improve service levels without increasing labour dependency
The Kardex Difference: Innovation Backed by Local Expertise
Successful automation is not just about technology. It is about delivery and support.
Kardex brings:
Local engineering presence – Local project teams who design, install and commission systems in-market.
Lifecycle support in New Zealand – Ongoing service, maintenance and optimisation from locally based technicians.
A growing installed base – A fast expanding portfolio of AutoStore systems operating across Australia and New Zealand.
As the fastest growing integrator of the automated storage and retrieval system (ASRS) of partner AutoStore, Kardex combines global AutoStore innovation with local operational understanding. Systems are modelled using real customer data, ensuring performance targets are met from day one.
Importantly, both Douglas and NZ Safety Blackwoods projects were installed alongside live operations with minimal disruption and delivered on time and on budget. Understanding the Financial Impact
The decision to automate is ultimately commercial.
To help businesses evaluate potential returns, Kardex offers the StoreX Calculator, enabling operators to estimate annual operational savings in minutes.
Automation is no longer experimental in Auckland. It is operating. It is delivering measurable gains. And it is helping local businesses grow with confidence.