Principal Contractor for a New Build: National Distribution Centre Automation at SLS
For a fast-growing distributor, a new building is a chance to rethink the entire operation rather than simply move it. Scientific Laboratory Supplies (SLS) took exactly that opportunity, and appointed CSL as principal contractor to deliver the automation, mezzanine, racking and shelving for its new National Distribution Centre. The project is a clear example of end-to-end national distribution centre automation, where the conveyor system is one part of a coordinated build.
SLS began trading in 1991 and has grown into a major independent supplier of laboratory equipment, chemicals and consumables.
Its new NDC at Fairham Business Park in Nottingham spans 40,000 cubic metres, over two and a half times larger than the previous Wilford facility miles away, and enables SLS to service 2,500 orders per day, three times more than was previously possible across a portfolio of 600,000 products.
Understanding the operation before designing the system
SLS approached CSL having identified the company as a partner capable of delivering their vision. Rather than move straight to a layout, CSL spent time understanding how SLS actually operate. The team visited the old Wilford site multiple times, talking to Operations Director Bruce Mowbray and to operatives on the floor, to build a picture of where the current process struggled.
They also visited the new Fairham site several times to advise on design, racking locations, mezzanine flooring, the walk-in fridge, and product storage and picking.
That groundwork fed directly into the design. The project objectives were specific: reduce operational costs, increase volume throughput, maximise warehouse cubic usage, improve accuracy, optimise the return on investment, and keep the solution as sustainable as possible.
The high ceilings at Fairham, 12 metres to the haunch, were treated as an asset to design around rather than empty space, using automation to make the most of the available height. Our warehouse and distribution work often starts with exactly this kind of site study.
“CSL were really responsive, our RFQ request came back really quickly and I think they went through about 9 designs and proposals to get to the one we are at today, but fully engaged throughout. The site has really high ceilings, 12 metres to the haunch so we wanted to use
automation to use this to our advantage and also to give us the efficiencies to grow the business.”
Bruce Mowbray, Operations Director, SLS
The automation solution
CSL installed a coordinated range of automation equipment from trusted partners, integrated into a single working system.
The line combines powered roller conveyor, double-stacked spiral conveyors to move product through the building’s height, automated checkweighing and labelling, and vision systems at key points, alongside storage and racking for over 1,500 pallets.
The double-stacked AmbaFlex spirals are central to using the building’s height, moving product efficiently between levels in a compact footprint. There is more on how these units work on our spirals page, and on the automated packing elements such as checkweighing and labelling that keep dispatch accurate at volume.
Delivered on time, with the client in the design seat
Because CSL acted as principal contractor, the business coordinated the four main elements of the project: the mezzanine, the racking, the automation and the shelving. The system went live in March 2024.
SLS had complete input into the designs throughout, which matters for a distributor that has to deliver exactly what its own customers want. CSL’s remit did not end at go-live, and the company was responsible for design, installation, commissioning support and the ongoing maintenance of the system.
That ongoing support is often where the long-term value of a system is protected. Planned mechanical servicing through CSL’s ConveyorCare programme keeps a high-throughput NDC running reliably once the installation team has left site.
“CSL came in with their team as principal contractor and managed the whole install and the four main elements of the project: the mezzanine, the racking, automation and shelving.
For us CSL delivered everything on time. We had complete input into the designs and for what the solution looked like. We have to deliver exactly what our customer wants so having the automation helps to achieve that.
“Bruce Mowbray, Operations Director, SLS
The value of a single principal contractor
On a project that combines a mezzanine, racking, shelving and automation, the interfaces between those elements are where problems usually hide.
A mezzanine set out without reference to the conveyor route, or racking positioned before the automation layout is fixed, creates clashes that are expensive to resolve once steel is in the building. Appointing one principal contractor to coordinate all four removes those seams.
● Mezzanine designed around the conveyor and spiral routes rather than in isolation.
● Racking and storage positioned to suit the picking and replenishment flow, here for 1,520 pallets.
● Automation specified as a single integrated system, from roller conveyor to spirals, checkweighing and labelling.
● Shelving and the walk-in fridge planned into the same layout, not fitted around it afterwards.
With one team accountable for all of it, there is a single point of responsibility for the programme and a single design intent running through every element.
For an operations director tripling daily order capacity on a fixed go-live date, that is what keeps the timeline credible.
Designing to use the building’s height
The 12 metre clear height at Fairham was treated as capacity rather than empty space.
Tall buildings only pay for themselves if product can move through the vertical space efficiently, which is where the double-stacked spirals and vertical storage earn their place.
Designing height utilisation in from the start, rather than filling the footprint and leaving the upper volume unused, is one of the clearest ways a new facility can get more throughput from the same ground area.
What SLS tells you about national distribution centre automation
The SLS project makes the case for a single accountable partner on a complex distribution centre build.
When the same team designs the automation, coordinates the mezzanine and racking, and supports the system afterwards, the interfaces between those elements are far less likely to become problems.
For an operation tripling its daily order capacity, that coordination is what makes an ambitious timeline achievable.
CSL provides design, installation and ongoing support for distribution centres of every scale. If you are planning a new facility or
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