The Quality Group automates with Lotus Robotics

The Quality Group (TQG) has set a new record at its fulfillment center in Elsdorf by achieving a daily throughput of 500,000 picks for the first time. This milestone was reached just over a year after the commissioning of the approximately 50,000 square meter distribution center, which plays a central role in the company’s e-commerce business. TQG, which distributes brands such as ESN and More Nutrition, specializes in sports nutrition and lifestyle supplements and serves an active online community.

Flexible Automation as the Key to Success

The achieved daily record highlights the importance of flexible automation solutions in a market characterized by rapid changes in demand. TQG has opted for the Robots-as-a-Service (RaaS) model from Locus Robotics to adjust the number of robots deployed based on order volume without incurring high initial investments. This decision allows the company to quickly scale capacities while keeping operating costs under control.

The implementation of automated solutions took place in several phases. Initially, 40 robots were deployed in a temporary picking area, followed by an expansion to 120 robots in the high-bay warehouse. In further steps, the fleet was increased to 260 and finally to 350 robots, which can be raised to up to 400 robots as needed. This flexibility has enabled TQG to exceed the 20 million picks mark within the first year of operation and to increase this number to over 30 million just a few months later.

Optimizing Processes through Intelligent Systems

A central element of the automation is the Locus Fast Pick solution, which is implemented at each pick station. This technology allows multiple robots to be dynamically assigned to a common picking area, creating a continuous sorting wall for employees. During sudden demand spikes, the AI-powered platform LocusONE™ automatically concentrates the robots and work orders on the relevant items.

Additionally, TQG operates special ultra-fast zones for planned campaign volumes. Products expected to experience high demand are positioned in these areas to further increase throughput. Separate replenishment aisles ensure that the picking operation continues smoothly even during intense replenishment cycles. This configuration allows for the processing of several thousand units per zone, with picker productivity ranging between 400 and 600 units per hour.

Cihan Yasar, Site Manager at TQG, emphasizes the need for operational flexibility: “To handle 60,000 orders per day with daily volume fluctuations, more than just pure automation is required. It demands operational flexibility without financial risk.”

Long-Term Partnership for Continuous Growth

The solution operates under the RaaS subscription model from Locus Robotics, which includes continuous performance optimization and 24/7 operational support. During peak times, the system can scale quickly and without structural interventions. LocusONE™ ensures that robots and workloads are dynamically distributed to secure throughput and service levels. Ongoing updates in AI, software, and hardware ensure that operations continuously evolve and adapt to demand.

Denis Niezgoda, Chief Commercial Officer International at Locus Robotics, highlights that the RaaS approach fundamentally changes the economics of warehouse infrastructure. “High-volume fulfillment processes no longer start with massive initial investments but with adaptability that scales with demand.”

Thus, the fulfillment center in Elsdorf is not only prepared for current order volumes but also for future growth phases and unpredictable demand developments.