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By deploying Exotec’s Skypod® system in Venlo, DSV has equipped itself with a flexible and scalable automation solution, designed to support its e-commerce growth over the next 8 to 10 years. Its inbound and outbound operations now run in a continuous, automated flow, in a warehouse built for the future.
The Skypod system at DSV Venlo
| Robots | Stations | Locations | Lines/hour | Height |
| 95 | 8 | 95,000 | 1800 | 8m |
DSV: a global leader facing the challenges of e-commerce
Present in more than 90 countries with over 150,000 employees, DSV is one of the world’s leading logistics operators, active in air, sea and road freight as well as contract logistics. Its teams manage supply chains every day for thousands of companies, from SMEs to large international groups.
With the rise of e-commerce, the Venlo site needed to evolve rapidly to meet the growing demands of its clients.
The challenges: agility, scalability, working conditions
A market that leaves no room for standing still
E-commerce comes with its own constraints: variable volumes, expanding product ranges, and seasonal peaks to absorb. The traditional logistics model was reaching its limits, and DSV needed an infrastructure capable of adapting without compromising its service levels.
The pressure on costs and workforce
DSV was facing growing tensions around recruitment and operational costs, while still having to meet the needs of its retail clients. Automation emerged as a strategic response and a concrete lever for improving working conditions.
An investment built to last
DSV was not looking to solve a one-off problem, but to equip itself with a solution capable of supporting its growth over 8 to 10 years, without overhauling its existing infrastructure.
“DSV needed an automated and scalable solution, tailored to our clients’ needs. Both to meet our current requirements and to support our growth for the next 8 to 10 years.”
The solution: a turnkey Skypod system
A fully orchestrated logistics flow
Exotec deployed 95 robots, 8 stations and 95,000 storage locations to cover the entire flow, from goods receipt to dispatch. The system handles order picking, reconditioning, replenishment and all inbound and outbound flows simultaneously, for multiple retail brands and different types of containers.
At the entry point, each parcel is identified and measured using a Cognex dimensioning and scanning arch. Cartons with a compatible format are automatically directed to the main flow; oversized cartons are redirected to the reconditioning stations, where operators transfer the contents into Exotec bins. The site also includes a dedicated returns mezzanine, connected to the rest of the system.
One point of contact, one integrated solution
Exotec coordinated the integration of all peripheral equipment: the Ciuch conveyor system including a tray loader enabling cartons to be placed on trays via the Elten solution, Sealed Air carton formers and sealers, as well as carton openers and labellers. This high-density deployment represented a significant integration challenge. DSV had a single point of contact to manage the entire project.
“Project management was considerably simplified thanks to a single point of contact at Exotec. We only had one party to coordinate on our side to deploy the entire solution.”
The results: transformed operations
From go-live, the on-site teams adopted the system with ease. The intuitive interface and support from the Exotec teams made the transition swift, with a tangible impact on working conditions.
“The team truly embraced the Exotec system and enjoyed learning this new technology from day one.”
DSV can now absorb changes in its business without overhauling its operations, whether that means new clients, new product lines or increased volumes. The system maintains service levels during seasonal peaks and helps make automation a lasting competitive advantage.