Unique new warehouse marks first step toward futureproof logistics for Coulisse

In 2024, Coulisse commissioned its new warehouse in the Dutch town of Enter. The warehouse is part of a larger masterplan that also includes a fully automated high-bay warehouse. The company asked Groenewout to carry out a feasibility study for the plans. The logistics consulting firm subsequently assisted in the selection of the warehouse equipment and the new WMS, and oversaw the entire project.

Coulisse is a global specialist in window coverings. What started as a trading company in 1992 is now known as the most innovative and inspiring window covering company in the world. It has enjoyed rapid growth ever since its foundation, in particular following the establishment of its own engineering department in 2004. Four years later, Coulisse launched its own modular concept. “Things have moved quickly, especially in the last few years,” says Thijs Prins, Supply Chain Director at Coulisse.

The company currently has around 300 employees and its products are sold in 90 countries worldwide, supported by its own sales offices in the US, UK, Australia and China in addition to the headquarters in Enter. Coulisse supplies window coverings made from all kinds of materials for all segments, and also provides the associated accessories such as rods, aluminum tubes, motors and traction cords. “We mainly supply to assembly companies, but we also sell to DIY chains and major retailers,” adds Prins.

Futureproof warehouse

As a result of the strong growth, however, the limitations of the logistics operation became apparent. The existing warehouse soon turned out to be too small, especially when the decision was made to increase stocks during the COVID pandemic. Prins: “We were forced to rent an additional 6,000m² of external storage space in addition to our own 10,000m². That was far from optimal, of course.”

The company was already thinking about designing a new logistics center. The growing inventory levels and rising number of stock keeping units (SKUs) accelerated that decision-making process. The goal was clear: a futureproof – and where possible mechanized – warehouse that would enable scalable growth and further reduce the lead times on customer orders. “In addition, the new facility had to be a pleasant and ergonomic working environment for our employees,” says Rob Looman, Operations Manager at Coulisse.

This led to the construction of a new 15,000m², 13m-high logistics center in the town of Enter. A different location was never even an option for the family business. “Enter has been our home since the company was founded, and it always will be. We value our good relationships with the local community and our employees, many of whom come from this region,” Prins emphasizes.

The right expertise is very welcome

Coulisse enlisted the help of Groenewout to verify the feasibility of the new distribution center and develop the detailed plans. Prins: “We don’t build a new, largely mechanized logistics center every day, so the right knowledge and experience is very welcome.” “On top of that, the dimensions of our products can be challenging: up to six meters long and weighing up to 75kg,” adds Looman.

Based on the data provided, Groenewout investigated which storage and handling methods would optimally meet Coulisse’s needs and requirements. “Among other things, we wanted to know whether we could mechanize parts of the operation, and how many FTEs we would then need. To provide answers, Groenewout performed a complete CAPEX and OPEX calculation,” says Looman. “Their pragmatic, no-nonsense approach is a perfect fit with our own way of thinking and working. They listen closely, make suggestions and are flexible. That’s how you arrive at the best solution together.”

Unique execution

In Coulisse’s case, the resulting solution is special for several reasons. The company’s strong focus on design is reflected in the unique execution of the warehouse. For example, the outer walls are constructed of bricks that were specially made for the project. And because of the strong ties with the community, Coulisse offered all the bricklayers in Enter the opportunity to be involved in the project. As a result, ten local bricklayers spent six months creating the logistics center’s exterior walls, which mimic the texture of a fabric roller blind.

Mix of conventional and mechanized processes

The interior is equally unique, with the logistics operation comprising a mix of conventional and mechanized processes. One conventional aspect is the Euro pallet racking. “That is where orders are picked from boxes,” explains Looman. “Previously, we did that at ground level only. Now, we pick on the first five of the eight storage levels, which has enabled us to significantly increase the number of picking locations while reducing replenishment work.”

The mechanized part of the warehouse is where long items such as aluminum roller blinds measuring up to six meters in length are stored and picked. Here, Coulisse uses an automated storage & retrieval system (AS/RS), in which the cassettes are transported to and from the picking stations by a mechanized crane.

Automated high-bay warehouse

The facility is part of a larger masterplan ultimately aimed at building a complete Coulisse campus alongside the A1 motorway. Phase 2 comprises the construction of an 18m-tall automated high-bay warehouse on the 7,700m² site adjacent to the new distribution center. “We will submit the permit application soon. We hope to start construction in 2026 so that our entire stock will be back in one location by 2027,” says Prins.

In the high-bay warehouse, items such as rolls of fabric and planks of wood measuring up to 3.60m in length will be stored fully automatically based on an RFID scan. After the goods have been unloaded using a telescopic conveyor, they will travel via a roller conveyor from the goods receiving area to the storage area. There, they will be put away in one of the six aisles using automatic cranes. In a goods-to-man concept, the cranes and roller conveyor will also handle the transport of outgoing orders to the various dispatch stations.

“In total, we will be able to store 99,000 units in the high-bay facility,” Looman explains. “The solution offers big advantages ergonomically. In addition, we will soon be able to identify each unique roll of fabric and access it directly with the crane. That will enable us to supply precisely the right roll and thus further improve the quality of our service.”

“Incidentally, Phase 2 was the first phase to be approved,” Prins continues. The design of the recently completed warehouse (Phase 1) stemmed from that decision. Prins: “The mechanization in the current logistics center is a logical consequence of the mechanization in the high-bay warehouse. Combining product groups in the cassette system made mechanization more cost-effective in the first phase too.”

Upgraded warehouse control

Based on the calculations, Groenewout also recommended upgrading the warehouse control system. Looman: “We were planning to migrate to a new ERP anyhow. But in the end we opted for a separate WMS, because that’s the best solution for the future. A different solution would have been better for the ‘as is’ situation, but in the ‘to be’ situation the new WMS will enable more flexible operations and more accurate fine-tuning. Once again, Groenewout provided us with expert support when selecting the WMS.”

“When everything is operational, we hope to ship all orders not only quickly, within 24 hours, but also error-free,” says Prins when asked about the future. “None of this would have been possible without Groenewout’s help.”

More information

If you would like more information about this project, please contact Dennis van Steen (tel. +31 76 533 04 40). For more information about Coulisse, go to https://www.coulisse.com

About the author

Mark Dohmen has been working as a journalist in the logistics sector for more than 30 years. After studying Logistics Management, he worked as an editor at the trade publications Transport+Opslag, Logistiek and Logistiek.nl, and was editor-in-chief of Logistiek Totaal and Warehouse Totaal. He now works as a freelancer, including producing articles and videos for logisticsinside.nl and logisticsinside.eu.