Malouf Achieves Faster Fulfillment With Upgraded Conveyor System

Malouf recently announced that its in-house team of engineers developed and implemented new software to the conveyor system at its Dallas warehouse building. This addition is one of several strategies the company is implementing to accelerate order fulfillment during COVID-19.

When purchased, the distribution center with six miles of conveyor belts consisting of 10 separate lines and three pick modules was lacking efficiency. To streamline the order fulfillment process, Malouf’s engineering team created an automated software for the conveyor system by utilizing the company’s award-winning warehouse and inventory management software.

“Over the years, we have tested and installed dozens of software solutions in our warehouses to increase our shipping speed and efficiency,” said Erfan Reed, Malouf engineering team manager. “When we acquired the Dallas warehouse, we identified an opportunity to integrate our in-house technology to provide better service to our retail partners.”

Reed and members of his team built new custom printed circuit boards (PCBs) and wrote software compatible with the building’s 20-year-old scanners, promoting quicker fulfillment and delivery times. Since applying these updates three months ago, the company has eliminated several hours of manual labor per week and decreased its processing time by nearly 50 percent per item.

“We know that fast and convenient shipping is crucial to our partners’ success, and we’re committed to their success every step of the way,” explained National Sales Manager Eric Holmstead. “At Malouf, we manage the order fulfillment process from start to finish to help our partners deliver the greatest value and service to their customers.”

Malouf is now implementing the same software in its newly acquired warehouse property in Delano, California. Previously a distribution center for Sears, the 1.2 million-square-foot building features 12 miles of conveyor belts with over 20 pick modules. Malouf expects the conveyor system to be ready later this year when the company begins shipping product from the facility.

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About Malouf:  A leader in the furniture and bedding industry, Malouf™ offers a wide range of innovative products including mattresses, adjustable bed bases, furniture, pillows, sheets, mattress protectors, bed frames and mattress toppers. Malouf™ products are available in over 15,000 retail partner locations in the U.S. and its growing international team now serves over 25 countries. Known for its commitment to quality, pricing and service, Malouf™ continues to expand its vertical integration and technology capabilities to better serve its customers with more than 335 global patents and trademarks. Malouf™, a Certified B Corporation®, was founded in 2003 by Sam and Kacie Malouf and is headquartered in Logan, Utah.