Torrid is one of the largest direct-to-consumer apparel brands in North America for women’s sizes 10–30. By introducing waveless fulfillment, VARGO® helped Torrid transform an existing operation into a scalable, high-throughput system — without major facility expansion or disruptive infrastructure changes.
Higher throughput from automation already on the floor
Increase in pick and matching UPH
Labor cost reduction
Order cycle time reduction
Sq ft reclaimed storage
As Torrid expanded to more than 600 stores worldwide and continued to grow its direct-to-consumer business, fulfillment operations began to reach the limits of their capacity. Despite prior investments in automation and labor, existing workflows were fragmented and unable to deliver the throughput and consistency required to support continued growth.
Torrid partnered with VARGO® to redesign operations around a continuous, waveless execution model. COFE® WES was deployed as an orchestration layer across Torrid’s existing automation, controlling mechanical elements while synchronizing labor, inventory, and workflows in real time.
Transition from an all-active pick model to a reserve replenishment model.
Eliminating mechanical buffer constraints that slowed product flow.
Retrofitting unit sortation from sort-to-chute to sort-to-putwall.
Implementing COFE® WES to orchestrate continuous, efficient execution.
VARGO® worked closely with Torrid’s leadership and operations teams to integrate COFE® into the existing technology platform. Rather than introducing unnecessary new equipment, VARGO® adapted automation and controls to the process requirements, limiting incremental capital spend and operational disruption.
Beumer cross-belt sorterMatthews automation controlsHighjump WMSDematic conveyor systems
The waveless fulfillment model delivered immediate and sustained improvements across Torrid’s operation.
Beyond the metrics, Torrid’s fulfillment operation became easier to manage, more predictable, and better positioned to support future growth.
Schedule an operational assessment, explore a COFE® demo, or visit a reference site.
