The answer came in the form of automation: Modula ML50D Vertical Lift Modules (VLMs). These high-density storage systems helped Outset Media regain valuable floor space and dramatically improve their picking performance allowing them to meet order demand more efficiently than ever before.
The Challenge: Capacity Constraints and Rising Demand
Outset Media’s Brampton warehouse handles a large portion of order fulfilment for both retail and eCommerce customers throughout Canada and the U.S. But as sales surged and SKU counts increased, the facility became over-capacity. Floor space was dominated by traditional shelving, which was no longer sustainable for their volume of small-item inventory.
Pickers were spending too much time walking between racks and searching for products, which limited how many orders could be completed per day. The team needed a solution that could dramatically condense their inventory footprint while enabling faster, more accurate order fulfilment.
The Solution: Modula ML50D VLMs
Outset Media installed 4 Modula ML50D Vertical Lift Modules to modernize their approach to storage and picking. These vertical storage systems maximize warehouse height rather than floor space, storing items in a series of enclosed trays that can be automatically retrieved with the touch of a button or scan of a barcode.
Once implemented, the VLMs became the primary storage location for the company’s direct-to-consumer inventory.
Key Outcomes from the Installation:
- Saved over 4,000 sq. ft. of floor space
- Tripled picker productivity – one operator now fulfils orders at 3x the previous rate
- Faster, more accurate picking with automated tray delivery and barcode scanning
- Streamlined DTC operations for seasonal and daily high-volume orders
Thanks to the system’s intuitive software, operators can access SKUs with ease, reducing physical strain and eliminating unnecessary steps. Orders that once took several minutes to pick can now be fulfilled in seconds.
Software Simplicity and Operator-Friendly Design
One of the defining strengths of the Modula system is its ease of use. The touchscreen interface and built-in barcode scanner made it easy for the Outset Media team to adopt the new technology with minimal training. Operators can quickly locate items, view inventory levels, and complete picks without needing to leave the access bay.
This simplicity not only speeds up fulfilment but also reduces the risk of human error – a major benefit in a high-volume environment where order accuracy is essential.
Long-Term Value and Scalability
The installation of the four VLMs not only solved Outset Media’s immediate space and efficiency challenges — it also positioned the Brampton facility for long-term growth. With the ability to adjust trays, manage SKUs digitally, and expand system capacity as needed, the warehouse is now equipped for the evolving demands of retail and eCommerce logistics.
By optimizing how products are stored, retrieved, and packed, Outset Media has created a warehouse workflow that is smarter, safer, and significantly faster.
Why It Matters
The decision to implement a Modula Vertical Lift Module was about more than solving today’s problems — it was about preparing for tomorrow. As Outset Media scales, the VLM will continue to adapt to their needs, allowing for fast SKU adjustments, integration with digital systems, and the ability to expand storage without increasing building size.
For a company that values both innovation and efficiency, the Modula VLM represents the perfect blend of modern warehouse technology and operational intelligence.
Thinking of automating your storage?
Get in touch with Greenspace Industrial to learn how Modula VLMs can unlock space, boost performance, and bring long-term value to your warehouse.
SOURCE: www.greenspaceind.com
KEYWORD’S: WAREHOUSE OPERATIONS | MODULA VERTICAL LIFT MODULE | GREENSPACE INDUSTRIAL | VERTICAL LIFT MODULES.