How Bronco Wine Scaled Distribution Throughput with a Three-Level Pick and Sortation System

The Client: Bronco Wine Company

Bronco Wine Company is a major U.S. wine producer with broad domestic and international distribution requirements. As order volume increased, Bronco needed to modernize distribution center execution to improve speed, reduce errors, and support tighter outbound scheduling.

FloStor partnered with Bronco during development of a new Ceres, California facility to engineer a high-throughput, accuracy-driven picking and loading operation.

The Challenge

• Route Loading Complexity: Thirty-two routes required nightly loading with reverse-stop truck sequencing.
• Time Compression: Existing process moved roughly 3,000 cases in about 12 hours, constraining dispatch windows.
• Facility Footprint Limits: Columnless building goals constrained available system real estate and staging options.
• Accuracy Risk: Paper-based picking and legacy conveyor handling reduced verification reliability.
• Dynamic Loading Requirement: Orders needed to be loaded on-the-fly without traditional staging buffers.

The Solution

FloStor designed a three-level pick-module and sortation architecture integrated with a new warehouse management system. The solution synchronized RF-guided picking, conveyor merges, barcode verification, and destination sort logic to support reverse-route loading and higher case throughput.

The operating model combined fluid truck loading lanes with manual palletizing stations and automated downstream wrap transfer, creating one coordinated outbound flow from pick to dock.

Systems Used

• Three-Level Pick Module: Case flow and pallet flow storage media consolidated SKU access and reduced replenishment burden.
• RF-Directed Picking Workflow: Real-time device guidance aligned picker actions to WMS order logic.
• Spiral, Sawtooth, and Recirculation Merge Design: Multi-line case convergence supported stable feed to sorting controls.
• Barcode Read and Sortation Verification: Destination confirmation and WMS feedback improved order-level accuracy assurance.
• Fluid Truck Loading and Palletizing Stations: Six extendable fluid lanes plus three ergonomic pallet stations supported mixed outbound profiles.

The Power of Integration in Action

FloStor’s integrator role linked WMS execution, pick behavior, merge controls, and final loading operations into one synchronized process. This enabled Bronco to shift from single-route sequential picking to multi-route concurrent fulfillment while preserving reverse-stop loading discipline.

Integrated data visibility at pallet stations and sorter checkpoints improved control and reduced exception-handling friction during peak dispatch periods.

The Results

Bronco significantly improved fulfillment velocity and outbound reliability without increasing labor hours. The new system increased throughput, reduced breakage risk from legacy roller behavior, and improved loading consistency against demanding route schedules.

Higher execution speed also expanded commercial flexibility by extending same-day order opportunities and improving customer service responsiveness.

Why This Worked

This deployment succeeded because Bronco and FloStor designed the DC around integrated execution logic instead of isolated equipment upgrades. Storage media, RF workflows, sortation controls, and dock loading were engineered to operate as one flow system.

• End-to-End Coordination: Picking, verification, sorting, palletizing, and loading were linked in one control model.
• Space-Constrained Design Discipline: High functionality was delivered within strict facility layout limits.
• Reverse-Route Loading Intelligence: Flow balancing supported transport-specific loading sequence requirements.
• Data-Backed Operator Execution: WMS-connected workstations and RF tools improved control and responsiveness.

Related Services

• Distribution Center Pick Module and Sortation Integration
• WMS-Connected RF Picking and Verification Design
• Fluid Truck Loading and Palletizing Workflow Engineering
• High-Throughput Outbound Operations Optimization