Wiggle ‘moved’ by CSL

Wiggle Ltd, the UK’s top online retailer for cycle, run, and swim gear, recently decided to relocate its operations to a larger, unified fulfilment centre in the West Midlands, from their multiple smaller sites in Portsmouth.

Selecting a Partner

In order to facilitate this transition, Wiggle undertook a rigorous tender process to find the right solution provider. Conveyor Systems Ltd (CSL) stood out for their ability to provide a well-demonstrated solution, which was visualised using the latest 3D CAD drawing software.

The Task

The task was to amalgamate packed orders from three pick/pack areas spread over three floors and categorise them into four dispatch zones for different carriers and services. The system was designed to handle up to 90 boxes per minute, ranging from small parts and clothing to large boxes containing bicycle wheels.

Wiggle ‘moved’ by CSL

CSL designed a custom conveyor system for Wiggle, over 900mm wide, accommodating various product shapes and sizes while addressing operational challenges. The mezzanine was divided into separate pick/pack zones to avoid disruptions during maintenance.

The system uses zero-line pressure accumulation conveyors to move orders to the sortation area, where powered Ambaflex spiral operators transport boxes to the ground floor. Packages are scanned, and high-speed switch sorters direct them to the appropriate dispatch lane.

CSL provided a complete turnkey solution, including control, installation, and commissioning. Dan Corrigan, Wiggle’s Programme Manager, praised the smooth installation and the clarity of CSL’s 3D visualization.

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