Direct Soccer, a specialist in customised football kits serving grassroots teams across the UK, has taken its operational efficiency to the next level by doubling the capacity of its AutoStore™ system. In December 2022, just two years after the initial system was installed, the company expanded from 8,000 to over 16,000 bins, along with adding more robots and workspace to seamlessly meet rising demand. 

This expansion has not only optimised workflows but also improved the company’s ability to handle seasonal spikes, reduce costs, and significantly enhance customer service.  

“Doubling our capacity has allowed us to improve storage, speed order fulfilments, and scale during busy periods, all while maintaining top-quality service,” explained Bryce Gibson, co-owner of Direct Soccer. 

Scaling up: Increasing storage and speed 

Since the initial AutoStore™ launch in December 2020, Direct Soccer has seen dramatic improvements in warehouse operations. The addition of 8357 more bins, five extra robots, and two new carousel ports has made the retrieval of stock faster and reduced manual handling. 

“With the expansion, we’ve eliminated the need for overflow storage and simplified our restocking processes,” said Bryce. “We now have more flexibility in handling daily orders and weekend surges without causing bottlenecks.” 

The extra robots and ports have increased the system’s bin presentation rate – the speed at which items are retrieved – giving Direct Soccer the ability to manage both regular and high-volume periods smoothly. 

Operational and financial savings 

The AutoStore™ expansion hasn’t just made Direct Soccer faster, it’s made the business more cost-efficient. By optimising its processes, the company has reduced headcount by three full-time positions, recouping significant annual savings. 

In addition, expanding the AutoStore™ system has freed up 210 square metres of operational space. This has helped reduce heating and lighting costs, lowering overheads and increasing energy efficiency. 

“The results are clear. We have not only doubled our storage capacity but also more than doubled our output,” Bryce said. Before the expansion, Direct Soccer dispatched 40 orders per hour; this number has now surged to 99 orders per hour, allowing them to meet growing customer demand with ease. 

Seamless expansion with zero downtime 

A key highlight of Direct Soccer’s system upgrade was the seamless way it was implemented without any slowdown or interruption to daily operations. Direct Soccer and Element Logic planned the project meticulously to avoid disruption. 

“The Element Logic team ensured the expansion was broken down into manageable stages, keeping everything on schedule and under control. When it came time to integrate the extension, we did it over a single weekend with zero downtime,” explained Joyce Gibson, co-owner of Direct Soccer. 

This smooth transition ensured that the company could keep fulfilling orders without delays, maintaining its excellent customer service during the critical holiday season. 

Serving grassroots sports 

For Direct Soccer, automation is more than just about operational improvements –  it’s about better serving grassroots football clubs and schools that rely on them for custom kits. By speeding up order deliveries and reducing errors, the company has streamlined the process for volunteer-led teams. 

“Volunteer clubs have tight schedules, so fast and reliable deliveries are crucial. With the upgraded system, we get kits out quicker, allowing these teams to focus more on the game,” Joyce said. 

The enhanced AutoStore™ system helps Direct Soccer simplify the complex logistics of making fully customised kits for grassroots sports teams, reducing the burden on both the company and its customers. 

Ongoing support from Element Logic 

Element Logic’s partnership with Direct Soccer didn’t end with the installation. The team provides continued support, ensuring the AutoStore™ system is maintained proactively. Regular system performance reviews and ongoing support have allowed Direct Soccer to operate at peak efficiency, even during periods of growth. Element Logic works flexibly around Direct Soccer’s schedule to avoid any disruption, further reinforcing seamless operations. This expertise also ensures the AutoStore™ system is prepared for future scalability, allowing the solution to evolve as the company continues to grow. 

Looking to the future 

The success of the AutoStore™ expansion has inspired Direct Soccer to explore further automation opportunities. The business has implemented automating bagging machines in its dispatch area and investigating robotic-assisted production to increase efficiency in other parts of the business. 

“We are constantly looking to improve,” Bryce said. “The AutoStore™ system has transformed our workflow. It allows us to scale quickly while maintaining speed and accuracy, helping us stay ahead of the competition.” 

For businesses considering warehouse automation solutions, Bryce and Joyce Gibson have simple advice: “Go for it. Automation allows you to grow faster than you expect, and the return on investment will surprise you.” 

The investment in warehouse automation has transformed Direct Soccer’s efficiency, enabling them to meet increasing demand while retaining their reputation for speed and reliability.  

Looking ahead, automation will continue playing a vital role in supporting the company’s growth strategy as it serves football teams across the UK. 

AutoStore™ at Direct Soccer: Key stats 

• Initial installation: December 2020 

• Extension completed: December 2022 

• Bin capacity: Expanded from 8,000 bins to 16,357 bins 

• Robots added: 5 robots (bringing the total to 12 robots) 

• Order dispatch rate: Increased from 40 per hour to 99 per hour 

• Labour savings: Reduced headcount by an additional 3 full-time staff 

• Total financial savings: £470,000 saved over two years on floorspace, manpower, and energy 

• Operational footprint: AutoStore™ uses less than a quarter of the available floorspace, optimising both storage efficiency and operational costs