Modexpress, a full-service logistics fulfillment partner for international fashion and lifestyle brands, runs warehouses across Europe. To meet growing demand and improve efficiency, the company is expanding its largest site in Helmond from 39,000 to 52,000 sqm. The goal has been to centralize inventory, optimize technological capabilities, and support future growth. Having relied on Astro WMS from Consafe Logistics for nearly a decade, Modexpress has now integrated advanced automation solutions, such as a high-capacity pocket sorter, that work seamlessly together with the WMS. This combination allows them to handle peak volumes more efficiently and reduce reliance on manual labour.
The Challenge
With growing order volumes, increasing labour costs, and short lead times, Modexpress faced operational challenges:
• Dependency on manual labour for picking and sorting, making operations costly and difficult to scale.
• Complex multi-channel logistics from the same stock that serves differentorders to B2B and B2C.
• Managing peak season demand with manual fulfillment without delays or errors.
• Need for an integrated system to connect warehouse management, automation solution, and transport operations.
The Solution
To improve operations and scale efficiently, Modexpress invested in automated sorting, packing, and fulfillment solutions. A pocket sorter now processes over 7,500 pieces per hour, while carton-forming machines reduce manual work in packing. Astro WMS now acts as the central system that manages the entire flow from B2B and B2C within a single automated process. This integration ensures the handling of multichannel fulfillment, has doubled picking speed, improved accuracy, reduced labour dependency, and made scalability possible.
Modexpress has been working with Consafe Logistics since 2016 with Astro WMS as a core part of their operations. This trusted partnership provided the foundation for a seamless transition to more advanced automation while maintaining the flexibility needed for the company’s future growth.
Key Benefits
• Picking speed nearly doubled due to fully automated sorting and packing.
• Higher accuracy with automated checks that reduce errors in picking, sorting, and packing.
• Labour savings by being less reliant on manual efforts.
• Scalability allows an expansion to be able to handle bigger volumes.
• Stronger service to B2B and B2C customers by improved accuracy and reliability in multi-channel fulfillment.
“We continue to invest in our partnership with Consafe Logistics because their solutions are deeply embedded in our infrastructure — it is the heart of our operations. Strong personal relationships and clear, direct communication between our teams were key to the project’s success. Collaboration was highly interactive, with both teams working closely together. Our hands-on approach to testing and implementation accelerated progress, ensuring a seamless rollout. As with any complex development, we faced challenges during testing, but we resolved them quickly and efficiently. Their team was always ready to step in, providing expert support whenever needed,” said Jan van Vlokhoven, ICT Director of Modexpress.
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