THG Fulfil deploys 430 robots to lift sortation capacity

THG Fulfil has deployed 430 Libiao Robotics sorting robots at one of its facilities, increasing daily sortation capacity to 625,000 units.

The system was integrated with its warehouse management system in 35 days and reached target volume within a week. The project used a Robotics-as-a-Service model instead of a large upfront capital investment.

At the site, sortation capacity rose from 250,000 units a day to 625,000 units a day. Throughput also increased by 11,151 units an hour, 34% above the initial target.

The deployment includes 14 induction stations and 80 Libiao 3D sorters, enabling dynamic sorting across 3,840 destinations. In total, 430 robots were introduced to support batch picking and sortation.

The system is delivering 99.9% sort accuracy and 99.9% uptime. THG Fulfil added that the change has reduced staffing needs by 45 full-time equivalent roles at a daily volume of 200,000 units.

Labour pressure

The investment comes as eCommerce operators face pressure from rising order volumes, demand volatility and labour costs, particularly during peak trading periods. Retailers and logistics providers have increasingly turned to warehouse automation to reduce dependence on seasonal labour and handle higher throughput requirements.

THG Fulfil said its previous constraints were in sortation and batching, where capacity limits and fixed infrastructure created bottlenecks. The company serves brands across beauty, nutrition, fashion, electronics and housewares.

The rollout has also enabled later delivery cut-off times, supporting next-day delivery cut-offs as late as 1am.

Global reach

THG Fulfil operates as part of THG Ingenuity and provides fulfilment and courier management services for eCommerce brands. It works with more than 250 courier partners across 195 countries.

THG Fulfil is also an official distributor of Libiao Robotics, giving clients direct access to the supplier’s automation systems. The arrangement links its fulfilment operations with a commercial role in distributing the same technology.

Libiao Robotics specialises in sorting systems for warehouses and distribution centres. These systems are designed to help operators handle large volumes of parcels or units by automating repetitive sorting tasks that would otherwise require more floor space or labour.

For THG Fulfil, the project marks a shift towards a more modular approach to warehouse automation. Using a service-based commercial model allows the company to add or adjust robotics capacity in line with changing order patterns rather than tying expansion to permanent fixed equipment.

The figures point to a focus on lowering cost to serve while improving handling speed and order accuracy. These metrics are closely watched by eCommerce brands, especially in categories where promotions, social media demand spikes and late ordering patterns can produce sudden surges in volume.

At a single facility, the new system has delivered 99.9% accuracy and 99.9% uptime, increased capacity by 150%, and reduced staffing needs by 45 full-time equivalent roles at a daily volume of 200,000 units.