Prestige Leisure, a leading distributor of promotional apparel, has announced the development of a new warehouse facility as part of a strategic investment in its long-term operational capabilities.
The project includes a significant expansion of warehouse capacity, alongside the implementation of advanced automation and supporting systems. To deliver this, Prestige Leisure has partnered with Ferag UK, drawing on its expertise in intralogistics and system integration.
Operating in a highly competitive fulfilment market, Prestige Leisure’s investment reflects a clear focus on strengthening efficiency, scalability, and cost control. The new facility is designed to support higher throughput, improve order accuracy, and provide the flexibility required to adapt to future growth.
A key feature of the project is the adoption of a goods-to-person solution, enabling more streamlined picking processes and optimised warehouse flows. The system has been designed with adaptability at its core, allowing the operation to evolve alongside changing business requirements.
Ferag UK has worked closely with Prestige Leisure throughout the project, supporting not only the technical delivery but also the overall solution design. The collaboration reflects a shared commitment to delivering a robust, future-proof operation focused on measurable performance outcomes.
Through Ferag’s Lowest Cost of Order Fulfilment approach, this investment enables Prestige Leisure to deliver exceptional service levels while remaining highly competitive in a demanding market,” said Nick Hughes, Managing Director, Ferag Solutions. “By focusing on operational efficiency and scalability, they are building a future-ready operation capable of supporting both current demand and long-term growth.”
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About Prestige Leisure
Established in 1992, Prestige Leisure has solidified its place as an industry leader, providing top-quality blank garments to printers and embroiderers across the UK and Ireland. Based in Livingston, Scotland features 200,000sq/ft of warehouse space and houses over 5.5 million pieces of stock. Throughout their history they have maintained a reputation for excellence and reliability, catering to the diverse needs of their valued customers.
About Ferag UK
Ferag Solutions supports companies in optimising their fulfilment operations as an experienced intralogistics integrator. By combining advanced automation, intelligent software and existing infrastructure, Ferag delivers flexible, scalable systems that improve efficiency, reduce process costs and ensure reliable performance.
With a strong focus on partnership, transparency and measurable outcomes, Ferag enables businesses to maintain control of their operations while preparing for future growth. As a single point of contact, Ferag offers end-to-end expertise from initial concept through to operational delivery, providing solutions designed to perform today and evolve for tomorrow.
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Planning a warehouse automation project, reviewing your current fulfilment operation, or exploring how to improve long-term performance?
Drop Nicholas a message to discuss your requirements, challenges and future plans. He can help you explore the right automation approach for your operation, from system integration and warehouse software to scalable fulfilment solutions designed around your business.
Nicholas Hughes
Managing Director, Ferag Solutions UK
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FAQs:
Prestige Leisure is investing in automation to improve operational efficiency, reduce fulfilment costs and strengthen its long-term competitiveness.
Its existing operation relies heavily on manual picking, resulting in lengthy pick routes and greater complexity around stock handling and order consolidation. In a highly competitive, low-margin market, the new facility will provide a more efficient and scalable platform for future growth.
The new facility is designed to reduce manual handling, simplify picking and consolidation, and improve order accuracy, stock integrity and administration.
It will also help Prestige Leisure manage rising operational costs while increasing the proportion of its product volume processed through automation.
Ferag UK has worked closely with Prestige Leisure to develop a solution around the long-term requirements of the operation, rather than simply delivering against the original project scope.
The partnership has been built around technical expertise, flexibility and a shared focus on achieving the right operational outcome. As requirements evolved, Ferag UK was able to challenge the original approach and help develop a stronger business case based on overall return on investment.
The original concept focused primarily on automating Prestige Leisure’s fastest-moving products. As the project developed, the wider operation was reviewed and the solution was expanded so that approximately 99% of product volume could be handled through the automated system.
The revised design includes a larger storage configuration, triple-deep storage and additional workstations, while maintaining the required throughput. This will reduce the need for separate manual processes and create a more streamlined operational flow.
The wider warehouse extension will bring together a HAI Robotics goods-to-person AMR system, a new warehouse management system and a new ERP platform.
Together, these technologies will support the transition from a largely manual operation to a more automated and coordinated fulfilment process. Ferag UK is acting as the intralogistics integration partner, working with Prestige Leisure and the wider project team to help align the automation, software and operational processes as part of the complete solution.
For Prestige Leisure, the new operation is expected to reduce fulfilment costs, improve productivity and support greater order volumes with increased accuracy and stock control.
Customers should benefit from more reliable fulfilment, fewer picking errors, stronger service levels and the potential for faster deliveries. Improved operational efficiency will also help Prestige Leisure remain competitive on pricing as customer demand changes.
The solution has been designed around flexible AMR technology, allowing storage capacity, workstations and operational processes to be adapted as requirements change.
The project has already demonstrated this flexibility. During the design phase, the system was significantly expanded and reconfigured without changing the fundamental automation approach. This provides Prestige Leisure with a scalable platform that can continue to evolve alongside the business.
