CVS Pharmacy Deploys Dual Robotics System Across Distribution Centers

CVS Pharmacy scales warehouse automation with three-vendor robotics strategy

CVS Pharmacy has deployed an integrated robotics system across multiple distribution centers, becoming the first retailer to implement a dual robotic automation architecture. The pharmacy chain works with three technology providers—AutoStore, Bastian Solutions, and Tompkins Robotics—to handle storage, software integration, and sorting operations.

At the company's Hainesport, New Jersey facility, hundreds of robots sort more than 10,000 products daily through an automated storage-and-retrieval system, according to Supply Chain Digital, which first reported the details.

Why it matters

The results from CVS's Lumberton, New Jersey distribution center demonstrate how combining complementary automation technologies can deliver step-change improvements in warehouse economics. The facility now processes 400,000 products daily—up from 150,000—while operating at 40% lower cost than other CVS centers. For retailers and logistics operators facing labor shortages and margin pressure, this multi-vendor approach offers a proven alternative to single-platform automation strategies.

How the integrated system works

Each technology partner handles a distinct function in the workflow. AutoStore manages batch picking and storage, transferring goods from employee-controlled induction stations to robot trays. Bastian Solutions provides the Exacta software layer that connects AutoStore to the downstream sorting system. Tompkins Robotics operates the tSort system, which uses more than 420 autonomous robots to sort products into totes designated for specific CVS locations.

The tSort system requires minimal operator training and no dedicated maintenance team. When a robot malfunctions, operators can reconfigure it within minutes. Tompkins Robotics has deployed over 30,000 tSort systems globally across more than 300 installations.

Performance metrics from Lumberton facility

The Lumberton distribution center, which uses all three technologies, has achieved several operational benchmarks:

• Pick accuracy exceeding 99.9%
• 40% reduction in operational costs compared to other CVS facilities
• Modular system reconfigurable in minutes without downtime
• Reduced physical strain and improved safety for warehouse employees

The 160,000-square-foot facility now processes 1.9 million units weekly. CVS plans to add 750 additional robots to match the capacity of a one-million-square-foot warehouse.

"We've been breaking records almost every week with the amount of volume that we're able to push through that building," said Jamie Tatum, Lead Director of Supply Chain Strategy at CVS.

The combined implementation has delivered what Tatum described as "unmatched efficiency, accuracy, and scalability while enhancing employee satisfaction."

Supply Chain Digital reported these details about CVS's warehouse automation partnerships and performance results.