Matalan, the leading UK retailer, is transforming its logistics operations through a growing partnership with automation specialist KNAPP. Since 2020, the retailer’s distribution centre in Knowsley, Liverpool, has evolved into a cutting-edge hub, with its fifth expansion, a multi-million-euro investment, set to double its original capacity by 2025.

Starting with a modest setup in 2021, the centre now boasts advanced systems like eight rack line shuttle systems, 16 picking and decanting stations, and 100,000-container storage. This modular growth approach has allowed Matalan to scale efficiently based on real operational needs.

“With KNAPP’s scalable logistics,” explains John Smith, Senior Logistics Network Development Manager at Matalan, “we have achieved a balance of investment and reward as well as growth and efficiency, whilst remaining dynamic.”

Key upgrades, including a second pocket sorter, automated data systems, and improved ergonomics for store fulfilment, have boosted Matalan’s order fulfilment accuracy to 99.8% and extended next-day delivery windows. The centre now processes up to 100,000 online orders daily, all while remaining operational throughout the expansion process.

The long-term collaboration between KNAPP and Matalan is an impressive showcase of scalable success. “For us, there are two sides to scalability,” explains Jack Gardner, Head of Sales Design Engineering at KNAPP UK. “On the one hand, our solutions can grow with our customers’ needs. On the other, we can integrate them seamlessly into the processes on site.”

This phased, strategic approach highlights how Matalan is building a scalable, flexible logistics model, making the most of KNAPP’s expertise without committing to full-scale automation upfront