Eder Goodman Case Study:Doubling Overnight Distribution Throughput
Conveyor Handling Company and Hytrol Conveyor Company helped Eder Goodman unite three distribution operations in one facility, connect approximately five miles of conveyor, and keep next-day deliveries moving on schedule.
Eder Goodman is a leading wine and spirits wholesaler serving customers across Connecticut. With more than 5,000 active SKUs and thousands of cases moving through its warehouse each night, the company depends on a compressed, carefully sequenced distribution cycle: orders arrive all day, routing begins in the evening, picking follows, and trucks are loaded for delivery the next morning.
When growth and acquisition plans created the need to consolidate three separate operations, Eder Goodman needed more than additional conveyor. It needed a coordinated fulfillment system that could move substantially more volume, load multiple trucks at once, preserve order sequence, and be installed without sacrificing a single nightly operating cycle.
“You just can't miss an operational cycle in our business.”
Cutter Smith, Co-President, Eder Goodman
The Operational Challenge
Eder Goodman's legacy system had supported the business well, but it was built around loading one truck at a time. Consolidating three companies into one facility changed the scale of the operation. The warehouse needed to process more cases per hour and feed several outbound trucks while keeping every route in the right sequence.
The timing left little margin for disruption. Roughly 90 salespeople transmitted orders throughout the day. Orders closed at 6:00 p.m., routing began by 7:00, case picking typically started at 9:00, and truck loading followed around 10:30 or 11:00. Any loss of capacity could put next-day deliveries at risk.
Installation added another layer of complexity: the existing system had to remain productive while the new one took shape around it.
The CHC Solution
Working with Eder Goodman, its consultant, and Hytrol Conveyor Company, CHC designed an integrated material handling system around the warehouse's overnight rhythm. The solution combines approximately five miles of conveyor, a two-level pick module, high-speed sortation, accumulation, warehouse controls, and AutoStore integration.
Instead of treating each technology as a stand-alone island, CHC connected the picking areas, pre-merge points, transportation conveyor, mezzanine sortation, and truck-loading lanes as one synchronized operation.
Expanded Picking Capacity
A two-level pick module and coordinated conveyor picking support the volume created by the three combined operations.
Unified Material Flow
Orders released to AutoStore and conveyor picking merge into one controlled stream before sortation.
Route-Based Sortation
A Hytrol ProSort 1431 directs cases to the correct outbound truck location while preserving order sequence.
Coordinated Controls
The warehouse control system releases waves and coordinates activity across the different areas of the operation.
Purposeful Accumulation
Transportation and accumulation conveyor create the buffering needed to sustain flow through the overnight cycle.
Room to Grow
The system supports current productivity goals while preserving capacity for future orders or acquisitions.
How the Automated Flow Works
Release in Waves
The WCS releases orders to AutoStore and the conveyor picking operation in coordinated waves.
Sequence at Pre-Merge
Products from three lines are organized at pre-merge so cases release in the correct order.
Transport & Accumulate
Merged cases move through transportation and accumulation conveyor to mezzanine-level sortation.
Sort to the Truck
The ProSort 1431 sends each case to the appropriate truck-loading location for next-day delivery.
Integration Details
The value of the system comes from how the components work together. CHC coordinated the material handling equipment, controls, software interfaces, installation sequencing, startup, and ongoing support needed to turn a complex footprint into a single operating process.
| System Area | Equipment / Function | Operational Purpose |
|---|---|---|
| Case Picking | Two-level pick module and conveyor picking | Support higher case volume from the consolidated operation. |
| Goods-to-Person Picking | AutoStore integration | Coordinate AutoStore releases with conventional conveyor picking. |
| Order Coordination | Warehouse control system | Release waves and synchronize work across multiple process areas. |
| Material Transport | Hytrol transportation and accumulation conveyor | Merge, buffer, and move cases while maintaining a controlled flow. |
| High-Speed Sortation | Hytrol ProSort 1431 | Direct cases to the correct truck-loading locations. |
| Installation Strategy | Phased installation and temporary legacy-line reroute | Keep outbound operations running while making room for the new pick module. |
Building the New System Without Stopping the Old One
CHC's project team staged the work around Eder Goodman's operating schedule. Early in the project, the team rerouted one of the existing conveyor lines to create space for the new pick module. That temporary configuration let the warehouse continue loading trucks as the new system was assembled and integrated.
The approach protected the current business while preparing the facility for its next stage of growth—an installation challenge that demanded as much coordination as the finished system.
Build for Tomorrow.
“The biggest consideration we had was to allow them to continue running on their legacy system while we were putting the new one in.”
Seth Karambelas
Project Manager, CHC
The Result: Twice the Throughput, Same Critical Window
The completed system enabled Eder Goodman to double distribution throughput while maintaining the overnight cycle its customers rely on for next-day delivery.
Before the project, completing a 7,000-case night was a major accomplishment. Today, that volume represents one of the warehouse's slowest nights, while the operation can reach 14,000 cases and complete the work in a reasonable amount of time.
The gain is not simply speed. Wave-based control and sequenced pre-merge release help cases stay in the right order as they travel from multiple picking areas to the sorter and then to the correct truck.
“Prior to this system, a 7,000-case night was huge for us. Now we do those numbers on our slowest nights, and we can go all the way up to 14,000 cases.”
Adam Casella, Warehouse Manager, Eder Goodman
A Partnership Built for the Long Term
Eder Goodman, CHC, and Hytrol have worked together on material handling solutions since 1996. That relationship did not end at system startup. CHC continues to connect with the warehouse team monthly, and often weekly, as operating needs evolve and new improvement opportunities emerge.
“The people that are doing the work for you are almost just as important as the quality of the product you bring. If you can put them both together, it's a total home run—and for us, it's been that.”
Cutter Smith
Co-President, Eder Goodman
Inside the Eder Goodman Operation
Ready to Improve Your Distribution Operation?
With decades of material handling experience, CHC designs and integrates complete systems that bring conveyor, controls, software, sortation, storage, and automation together. Whether you need to increase throughput, consolidate operations, or modernize an existing facility, our team can develop a similar solution tailored to your workflow, space, and growth goals.