Dematic has partnered with one of Australia’s leading wholesale distributors, Metcash, to deliver a state-of-the-art goods-to-person (GTP) automation solution at its new distribution centre in Truganina.
Powered by Dematic Multishuttle technology, the system is designed to increase efficiency, reduce operational costs and support scalable growth as Metcash modernises its Victorian supply chain.
Metcash has consolidated its Victorian operations from a multi-shed site in Laverton into a single 115,000 square metre distribution centre to future-proof its supply chain.
The ageing mini-load system at Laverton, in place for nearly two decades, had become difficult to maintain, while the fragmented layout limited efficiency and flexibility.
To support its growth and diverse retail network, Metcash selected Dematic to deliver a flexible, high-performance goods-to-person automation solution tailored to its modernised operations.
“The challenges of operating across multiple sites made it clear we needed a smarter, more integrated solution,” says Victor Cleves, Head of DC Automation and Design at Metcash.
“Bringing everything under one roof was about creating a foundation that could support both current demands and future expansion.” said Cleves
At the heart of the new system is a high-density Dematic Multishuttle with seven active pick stations and capacity to scale. Dematic’s patented Inter-Aisle Transfer (iAT) technology enables dynamic bin movement, allowing any SKU to be accessible from any station.
Flex Shuttles in the sortation buffer help manage varying product sizes and fulfil diverse customer orders while supporting tight truck dispatch schedules.
The system also handles fragile items like wine bottles, a key requirement during tender. “Operator wellbeing was also a key focus for our business,” Cleves explains.
“Dematic’s Gen3 pick stations, especially the adjustable platforms and powered lift-and-rotation tables, made a huge difference in ergonomics and safety. It’s been a real game changer for our team.” he said.
A standout feature of the project was Dematic’s ability to integrate with two warehouse management systems – one for grocery and one for liquor. This ensured continuity while simplifying workflows.
The transition to Truganina was carried out in four stages, including a dedicated automation cutover. Laverton operations ceased on a Thursday, and by Monday, Truganina was live and fulfilling orders.
“This was a high-pressure transition that required careful planning, strong operational discipline, and a lot of support. Dematic delivered months of structured training and hands-on commissioning, gradually bringing our team into the process,” said Cleves
“By the time go-live came around, our operators had already been running parts of the system themselves, so they were confident and ready.” he said.
Dematic’s strong local presence helped ensure a smooth rollout. With more than 345 service professionals across Australia and New Zealand, Metcash had access to on-the-ground expertise and spare parts when needed.
“Having a strong local service team was a huge advantage for us,” says Andrew North, Metcash Victorian State Logistics Manager.
“It meant we had immediate access to the support we needed, whether it was for technical advice, parts, or on-site assistance. That level of responsiveness gave us real confidence during the transition and set us up for long-term success.” said North
Since go-live, higher pick rates have enabled Metcash to optimise its shift structure, improving resource utilisation and overall operational efficiency.
The system’s built-in redundancy has also delivered more consistent and reliable inventory access compared to the previous mini-load setup.
“The new system has allowed us to significantly improve efficiency and better manage our labour requirements,” says North.
“The visibility we now have around long-term maintenance and planning also means we can be more proactive with our servicing schedule and allows us to react quickly to retailer and market needs.”
Dematic also introduced a Lifecycle Cost Plan, providing forecasts for capital and maintenance spend across five, ten and fifteen years.
Dematic Business Development Manager Terry Jamieson said, “We’ve worked hard to be the partner Metcash can depend on, from design through to daily support,”
“We’ve built something together that’s not just functional, it’s future-proof,” Jamieson concludes.
Headquartered in Atlanta and part of the KION Group, Dematic operates in over 26 countries with R&D centres, manufacturing facilities, and service hubs, employing around 10,000 people to deliver automation solutions for many of the world’s leading brands.
