HelloFresh

Meal Kit Tycoon Adds 10 Kitting Lines Without Expanding Its Footprint

HelloFresh meal-kitting operation using UNEX FlowCell flow racksHelloFresh offers subscribers more than 20 meal options each week. As demand grew, the meal-kit company needed to increase fulfillment capacity and accommodate additional meal-kitting lines without expanding its existing facility.

The new storage solution needed to maximize available space while supporting frequent product changes, efficient replenishment, and a more ergonomic working environment.

To meet these challenges, UNEX evaluated different roller configurations, rails, and operating heights to develop a customized FlowCell modular flow rack solution. The system was engineered around HelloFresh’s specific meal-kitting processes to improve material flow, support employee efficiency, and increase production capacity within the existing footprint.

The customized solution allowed HelloFresh to:

  • Expand from 18 to 28 meal-kitting lines, a 56% increase

  • Add capacity without consuming additional floor space

  • Create return lanes for empty boxes

  • Make empty-box collection easier for replenishers

  • Improve workplace ergonomics

  • Adapt efficiently as products and meal options change

Download the HelloFresh case study to see how FlowCell helped the company expand fulfillment capacity, improve ergonomics, and prepare its operation for continued growth.

Download the Case Study