EcoPocket® at Matalan: performance that convinces

Industry

Apparel, Homeware

Product

EcoPocket®

Driven by the success of the first project, further expansion phases followed at the Knowsley site. Among other measures, a second DFT pocket sorter was implemented, along with a KNAPP Evo Shuttle 1D automated warehouse that went live in 2024. These steps marked the transition from isolated improvements to a systematic omni-channel optimization. As a result, Matalan evolved into one of the most high-performing omni-channel players in its industry.

Start Es hängen zahlreiche Kleidersäcke aus Kunststoff an einem Förderband, über ihnen leuchtet Neonlicht, und der Blick fällt auf die ordentliche Anordnung der Kleidungsstücke, die auf ihre Bearbeitung oder Abholung warten.

Facts and Figures

The benefits of automation are clearly proven:

Schwarz-weiße Strichzeichnung einer Uhr, die die Uhrzeit 2:00 anzeigt, mit Bewegungslinien auf der linken Seite, die Bewegung oder Dringlichkeit suggerieren.

Next-day cut-off extended by six hours

A black and white line drawing of a rocket ship with a circular window, tilted upward as if launching, with lines behind it representing movement or speed—symbolizing the swift efficiency of spare parts logistics.

Significantly reduced lead times from order to delivery

Eine gestresst wirkende Person sitzt an einem Schreibtisch, den Kopf in der Hand und einen Laptop in der Nähe. Zerrissene Papiere, eine Kaffeetasse und ein Push Tray Sorter stehen neben einer Uhr, die 3 Uhr zeigt, auf dem Schreibtisch und deuten auf arbeitsbedingten Stress hin.

Picking accuracy increased to: 99.8%

Es werden fünf Würfelumrisse gezeigt. Vier davon sind in einem Quadrat gruppiert und ähneln einem Push Tray Sorter, wobei ein Pfeil auf den oberen linken Würfel zeigt. Der fünfte Würfel befindet sich oberhalb der Gruppe, leicht nach links versetzt.

Throughput capacity of up to 100,000 orders per day

Eine Person sitzt im Schneidersitz in einer meditativen Haltung, die Hände ruhen auf den Knien. Darüber schwebt ein abstraktes schwarzes Wirbelsymbol, das für Achtsamkeit oder Energie steht, während ein Push Tray Sorter-Motiv den schlichten weißen Hintergrund dezent akzentuiert.

A one-touch omni-channel operation from a shared inventory pool

Software as a Game Changer: from an e‑commerce system to an omni‑channel hub

A person in a high-visibility vest works at a station, placing an EcoPocket item on a tray in front of a computer monitor displaying scanning instructions and diagrams in a warehouse or fulfillment center.

Through targeted DFT software adaptations, a system originally designed solely for e‑commerce was transformed into a powerful hybrid omni‑channel setup. Today, store orders also run through the pocket sorter — with impressive impact:

A 200% increase in efficiency in store order processing

This is exactly where DFT’s role as the KNAPP Group`s specialist for sorting and sequencing truly pays off.

A look into the future

The scaling journey continues: In April 2025, the fifth expansion phase was commissioned. In 2026, a Dynamic Pocket Storage system with a capacity of 30,000 pocket will go live, primarily handling fast movers. Further plans for 2027 include, among other things, eight shuttle aisles, eight Pick-it-Easy pocket workstations, 16 picking and 16 decanting workstations, as well as five shipping docks — all implemented while operations continue uninterrupted.

Numerous plastic garment bags hang from a conveyor belt, illuminated by neon lights, and the eye is drawn to the neat arrangement of the garments waiting to be processed or collected.

Industry-wide recognition

A group of people dressed in formal attire stand on stage, smiling and posing for a photo at the Supply Chain Excellence Awards 2025, with a large event sign and EcoPocket branding visible in the background.

On November 6,2025, the joint achievement was officially recognized: Matalan, together with Knapp and DFT, received the prestigious national “The Supply Chain Excellence Awards” in London. A strong confirmation from the industry and clear evidence of the successful, long-term collaboration with Matalan.

Ein lächelnder Mann in einer gelben Warnweste steht mit verschränkten Armen in einem großen, gut beleuchteten EcoPocket-Lagerhaus, in dem im Hintergrund Maschinen und Geräte zu sehen sind.

"The Solution that we have build at Matalan with our partners is transformational, innovative and reliable"

Head of Supply Chain Solutions & Systems - Matalan

Eine Frau in einem blauen Pullover und einem schwarzen Blazer steht lächelnd in einer modernen Industrie- oder Fabrikumgebung, im Hintergrund sind Maschinen, Förderbänder und Computerbildschirme zu sehen.

"The DFT solution has enhanced our customer journey, and this has helped us now, as we have extended our next-day delivery cut-off by six hours"

Supply Chain - Solutions Implementation Manager - Matalan

Drei Personen mit gelben Sicherheitswesten stehen und lächeln in einer Lagerhalle mit Industrieregalen und EcoPocket-Geräten im Hintergrund. Zwei Frauen stehen auf beiden Seiten eines Mannes, die alle für das Foto posieren.

"Winning one of the most prestigious awards in our industry — The Supply Chain Excellence Award — together with our customer Matalan and for my company DFT/KNAPP marks one of the most memorable moments in my over 30-year career in Logistics and Material Handling Systems."

General Manager UK & IRL - DFT

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Matalan

Matalan is a British fashion and homeware retailer founded in 1985. Today, the company operates more than 230 stores as well as international franchise locations. Matalan stands for modern, value‑driven clothing and home accessories for the whole family and attracts millions of loyal customers every year.

Luftaufnahme eines großen Lagerhauses mit weiß-grünem Dach, umgeben von Parkplätzen, Lastwagen und nahegelegenen Bürogebäuden, eingebettet in eine grüne, ländliche Landschaft.

EcoPocket®: Intelligent pocket‑sorter technology for multi‑client fulfillment

Aerial view of a large warehouse with a white and green roof, surrounded by car parks, lorries and nearby office buildings, set against a green, rural landscape.

The EcoPocket® solution from DFT is a highly flexible pocket sorter system for the automated processing of hanging and flat goods in a single material flow system. It is particulary suitable for industries that require high sorting performance, cross-channel sequencing, and dynamic buffering. Thanks to its modular architecture, scalable capacities, and versatile integration options, EcoPocket® supports complex fulfillment processes from item procurement to sorting and sequencing to shipping preparartion.

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