New Distribution Centre Uses Robotics and Smart Warehouse Technology to Improve Storage, Picking and Shipping Operations
Grand Prairie, Texas, 14 October 2026 – Cutter & Buck, a US apparel company, has opened a new automated distribution centre in Grand Prairie, Texas, strengthening its fulfilment network across North America. The facility, which officially opened on October 9, is designed to help the company manage growing order volumes while making warehouse operations faster and more flexible.
The new centre uses advanced warehouse automation to organise inventory, retrieve products and move orders through different stages of fulfilment. Its launch reflects the growing role of robotics and intelligent software in helping businesses manage increasingly complex distribution operations.
The facility features 50,502 storage bins, 32 AutoStore R5 Pro robots and 13 work ports. Kardex FulfillX warehouse execution software coordinates the automated storage and fulfilment activities, helping products move efficiently through the system.
According to the project specifications, the system is designed to achieve 1,256 bin presentations per hour. Simulations have recorded an average of 1,284 presentations per hour, demonstrating the system’s planned capacity to support high volume warehouse operations.
The automated storage system is connected to a conveyor network that links it with downstream operations. These include embroidery, routing, print and apply labelling, and shipping. This integrated setup allows the centre to handle both undecorated apparel and customised orders.
Bringing these activities together helps create a more connected fulfilment process. Rather than treating storage, product customisation and shipping as separate tasks, the facility links them through an integrated workflow. This is particularly important for apparel businesses that manage different product types and customer requirements.
Joel Freet, CEO of Cutter & Buck, said the company’s experience with automation at its Renton facility in Washington helped shape the new Texas operation. The company has used lessons from its earlier installation to develop a facility suited to its future business needs.
Cutter & Buck first introduced an AutoStore system at its Renton facility in July 2023. That installation began with more than 34,000 storage bins and 54 robots. The company later expanded the system by adding another 9,962 bins and additional picking ports to accommodate rising order volumes and a wider product range.
The new Texas centre builds on that experience while providing additional fulfilment capacity in another major US market. Its modular design also allows robots and work ports to be added independently as demand changes.
This flexibility can help businesses adjust warehouse capacity without redesigning the entire operation. As order volumes fluctuate, scalable automation provides a way to expand processing capabilities in stages.
The opening highlights how warehouse automation is becoming an important part of modern supply chain management. Robotics, warehouse execution software and integrated conveyor systems can help companies coordinate inventory movement and order processing more efficiently.
For retailers and manufacturers, the challenge is not simply storing more products. They must also manage customisation, maintain accurate inventory records and move orders through fulfilment operations with fewer delays.
Cutter & Buck’s new facility demonstrates how an integrated distribution system can support these needs. As businesses continue to adapt to changing customer expectations, scalable warehouse automation is likely to remain an important consideration in distribution planning.
By combining robotic storage with connected fulfilment processes, the Texas centre gives Cutter & Buck a flexible foundation for managing its expanding distribution requirements.
