Featuring KNAPP’s proven Evo Shuttle and pocket sorter technologies, the automated solution has enabled Matalan to push its next-day delivery order deadline for online customers back by 6 hours and reduced the average time from order placement to delivery by 48 hours.

Five system extensions

The system, which went live at Matalan’s omnichannel distribution centre in Knowsley in 2024, was implemented to enhance the retailer’s e-commerce operations and enables one-touch omnichannel distribution from a single pool of stock. Matalan also awarded KNAPP a resident service contract to look after the new and existing automation, as well as legacy systems from third parties. Following its successful collaboration with KNAPP, Matalan has placed orders for five extensions of the solution at Knowsley, including systems for fulfilment of retail store orders.

Enhanced fulfilment accuracy

The automation installed in 2024 raised Matalan’s efficiency in e-commerce significantly and improved order fulfilment accuracy to 99.8%, while also extending the order cut-off time for next-day delivery from 4pm to 10pm. In 2025, store fulfilment was modernised with ergonomically designed goods-to-person workstations replacing manual picking.

100,000 online orders a day

Today, Matalan’s distribution centre is capable of one-touch omnichannel distribution from a single pool of stock, processing up to 100,000 online orders a day. When the latest expansion project – which will make the automated system double its original size – is completed, the Knowsley DC will feature eight rack lines of Evo Shuttle, two pocket sorters, eight pocket induct stations, 16 picking workstations, 16 decanting workstations and five dispatch ramps.