Engineered Solutions | Complete Warehouse Automation+ Engineering Solutions

ABOUT ENGINEERED SOLUTIONS

Standard equipment
has limitations.
Custom engineering
doesn't.

Off-the-shelf automation fails because your warehouse isn't off-the-shelf. Instead of forcing you to change your processes, we design around how you actually operate.

No matter what your warehouse is handling—fragile electronics, temperature-sensitive pharmaceuticals, or managing oversized industrial components or otherwise—we design systems that work within your operational constraints while maximizing efficiency.

SERVICES

Engineering
solutions for
every warehouse
challenge.

Engineered systems for material handling, storage optimization, picking acceleration, and specialized operational requirements. Our engineering team has developed solutions for warehouses processing everything from 500 orders per day to 50,000+ daily shipments.

High-Speed Material Handling

Move more product with less labor through conveyor systems designed for your specific throughput requirements. Our PLC-controlled systems integrate with any existing software / controls currently in the network, along with our in-house software suite, Clarity™, for real-time monitoring and predictive maintenance.

Custom conveyor configurations for any space
High-speed sortation systems
Automated static & mobile robot fleets that scale with demand
Print-and-apply systems for any label requirement

Smart Storage Systems

Maximize storage density while improving retrieval times through automated systems that think ahead. ASRS integration with receiving operations eliminates manual putaway and optimizes replenishment.

ASRS design and installation for maximum density
Automated putaway directly from receiving
Intelligent retrieval based on pick patterns
Inventory tracking with zero manual counting

Picking That Scales

Batch picking with unit sortation delivers the highest productivity gains in warehouse operations. Our systems learn from your order patterns to optimize pick paths and reduce travel time.

Batch picking systems that adapt to order volume
Unit sortation for accurate, fast fulfillment
Pick-to-light integration for error reduction
Custom picking solutions for unique products

One-Off Custom
Engineering

When standard equipment won't work, we design and build what will. Our engineers have created custom sorters, robotic pickers, and specialty machines that solve unique operational challenges.

Custom unit sorters for fragile products
Robotic picking systems for irregular items
Automated carton erection and sealing
Specialty conveyance for temperature-controlled products

OUR PROCESS

Evaluation

Our team works with you to identify goals, understand your current state, and build a phased plan to tackle current challenges.

Solution Development

Top Hat identifies potential solutions for your approval, develops a process plan, and finalizes requirements for the project(s).

Solution Implementation

We coordinate purchasing of all materials, technologies, and resources needed. Then, after implementation, we begin volume testing.

Solution Optimization

We use initial data to optimize technology, solutions, and processes.

Solution Support

Our team remains available for both remote and on-site to assist with training, processes, and support.

Warehouse optimization system

Take control with
Clarity^TM

Every engineered solution connects to our Clarity Warehouse Optimization System. No need to manage multiple vendor interfaces. With Clarity, you get unified control, real-time analytics, and predictive maintenance for all automation systems.

Key capabilities:

Single dashboard for all automated equipment
Predictive maintenance alerts before failures occur
Real-time performance analytics across all systems
Integration with existing Warehouse Management Systems (WMS), conveyor systems, advanced automation, and handheld devices currently in network
Tablet-based troubleshooting and system management
Machine-learning powered software that automates slotting and replenishment, labor management, and warehouse execution

Learn more about Clarity

MORE ABOUT LIFECYCLE SERVICES

Frequently Asked Questions

What makes Top Hat's lifecycle approach different from traditional warehouse consultants?

Most consultants focus on single phases. Thanks to our experience, we’re able to provide continuous support from initial strategy through daily refinement. We understand both the strategic vision and operational realities of warehouse management.

How do you minimize disruption during warehouse upgrades?

Our phased implementation approach allows you to maintain operations while upgrading systems. We coordinate all activities to minimize downtime and provide on-site support during transitions to ensure smooth operations.

Do you work with existing warehouse management systems?

Yes, our solutions integrate with any existing Warehouse Management Systems (WMS), conveyor systems, advanced automation, and handheld devices currently in network. Plus, our Clarity WOS acts as an intelligence layer that enhances your current systems without requiring data migration or workflow changes.

What types of warehouses do you work with?

We serve operations from startup e-commerce fulfillment to Fortune 100 distribution centers. Our scalable approach works across industries including retail, manufacturing, third-party logistics, and direct-to-consumer operations.

How do you measure success and ROI?

We establish clear KPIs at project start and provide ongoing performance tracking. Typical results include 20-50% in labor savings, 40% increase in capacity, 90% reduced leave-behinds, 90% improvement in critical pull times.

Looking to optimize your warehouse’s operations?

Optimize your warehouse with a partner who understands the entire lifecycle. Our team brings decades of experience helping businesses achieve operational excellence and sustainable growth.

Schedule a call

Automation Solutions

Engineered for Your Operations

Standard equipment
has limitations.
Custom engineering
doesn't.