Companies seeking a new distribution center site will find a lot to love about Virginia, including a deepwater port and its location in the middle of the Eastern Seaboard.
Susan Lacefield has been working for supply chain publications since 1999. Before joining DC VELOCITY, she was an associate editor for Supply Chain Management Review and wrote for Logistics Management magazine. She holds a master's degree in English.
For 45 years, Virginia has been proclaiming to the world: "Virginia is for lovers." The state's travel and tourism ad campaigns have also declared at various times that "Virginia is for history lovers," "Virginia is for beach lovers," and "Virginia is for mountain lovers." State economic development groups might like to add one more slogan: "Virginia is for logistics lovers."
With a deepwater port capable of receiving the giant post-Panamax megacontainerships and with a location in the center of the Eastern Seaboard, Virginia has attracted companies like Amazon.com, Lumber Liquidators, and Ace Hardware, all of which have opened "big box" distribution centers (those larger than 300,000 square feet) in the state. In addition, industrial real estate developer CenterPoint Properties recently opened an intermodal center near the port that includes 5.8 million square feet of large and desirable Class A distribution and warehouse space.
Why is the commonwealth generating all this logistics love? Here are a few reasons.
YOU CAN GET THERE FROM HERE
If you're looking to locate a single distribution center on the East Coast, Virginia makes a lot of sense. The state lies between the major consumer markets of New York/New Jersey and Atlanta and northern Florida. It also provides easy access to Midwest markets.
"We typically tell folks that from central Virginia, you can access about 40 percent of the U.S. population within a day's drive," says Rob McClintock, director of research for the Virginia Economic Development Partnership. "That's a big chunk of the market right there. And if you just draw a radius of 750 miles, you hit 55 percent of the population. So you can get there from here. And you can get your stuff there from here."
By "there," McClintock doesn't just mean the domestic U.S. market. "We like to think of Virginia as really a gateway for the rest of the world," he says.
The Port of Virginia serves as the state's point of entry for international commerce, offering connections to about 200 countries, according to McClintock. The port's core asset is Hampton Roads Harbor, which, at 50 feet of depth, shares with Baltimore the distinction of having the deepest water of any East Coast port. The water depth is expected to make Hampton Roads inviting to super post-Panamax vessels, which many experts believe will increasingly be used to serve the East Coast once the expanded Panama Canal opens.
Another attractive feature of the port, according to Russell Held, the port's vice president of economic development, is that it has room to grow. The Port of Virginia is the only port on the East Coast with congressional authorization to deepen its channels to 55 feet, and the rivers that serve the port are free of obstructions such as bridges, rail crossings, or power lines that would restrict large vessels from entering the port. Furthermore, the port will be looking to expand its Virginia International Gateway Terminal within the next five years and is "roughing out" a possible 600-acre expansion site for a marine terminal on Craney Island in the harbor.
"We are possibly the only port in the U.S. that can show how it can expand not only next year but also 30 years in the future," says Held.
Business at the port is driving an increase in warehouse and DC development along the I-64 corridor from Hampton Roads to Richmond, according to Mark Levy, managing director and the mid-Atlantic logistics and industrial practice group leader for the commercial real estate firm JLL. Most of the DCs near the Hampton Roads port are used for transloading and breakbulk services. Because Hampton Roads lacks a large population base, it doesn't have many big box distribution centers, Levy says. Instead, companies like Amazon are locating their million-square-foot mega-DCs near the state capital in Richmond, which is situated halfway between the port and the major consumer market of Northern Virginia, which surrounds Washington, D.C., says Levy.
Vitamin Shoppe, a health and wellness retailer, last year opened a 311,740-square-foot distribution center in Ashland, Va., about 19 miles from Richmond. After an exhaustive site selection process, the company chose Ashland over other sites in Virginia and North Carolina. "It is a great location situated right off I-95. The proximity to a major highway serves us well in getting shipments out quickly, as we move most of our freight by truck," says Rich Tannenbaum, Vitamin's Shoppe's senior vice president, supply chain and information technology.
Virginia's infrastructure enables it to support other modes of transportation. For example, Virginia has the third-largest state-maintained highway system in the country, with six major interstates. Two Class 1 railroads serve the port: Norfolk Southern and CSX, both of which are headquartered in the state. Currently, 34 percent of the port's cargo arrives and departs by rail, the largest percentage of any U.S. East Coast port.
In Northern Virginia, Dulles International Airport serves as a major hub for both passenger traffic and cargo. According to McClintock, there is enough available space around Dulles that the airport could expand its capacity by a few hundred acres.
Virginia's maritime traffic is not limited to oceangoing vessels. Two and a half years ago, the port established a barge service from Hampton Roads to the Port of Richmond on the James River. Barge traffic has grown to the point where service is now offered three times a week, according to McClintock.
VIRGINIA IS READY TO WORK
Companies like Vitamin Shoppe are finding that Virginia doesn't just offer the physical infrastructure to support a distribution center; it can also provide the workers needed to staff that DC. "The Ashland area has been very welcoming ... and we have been able to find many skilled, qualified candidates to join our team," reports Tannenbaum.
Overall, the labor force in Virginia is growing at a rate that's twice the national average, according to the Virginia Economic Development Partnership. In the logistics and distribution sector alone, Virginia employs 68,500 people.
Every region of Virginia is served by community colleges, some of which offer truck driving schools, forklift driving academies, and warehouse management system training. In addition, Virginia boasts a network of universities that provide logistics-focused research and education. Old Dominion University, located in Norfolk, is known for its Maritime Institute, which provides maritime, port, and logistics management education, training, and research. The recently formed Commonwealth Center for Advanced Logistics Systems connects local businesses seeking help resolving logistics problems with students and professors at the University of Virginia, Virginia Commonwealth University, Virginia State University, and Longwood University.
The labor market also benefits from the strong military presence in the state. According to McClintock, 23,000 people a year are being discharged from the military and are looking for work in industry. Many of these veterans possess significant logistics skills because Fort Lee in central Virginia is the Army Sustainment Center of Excellence, a focused training base for military supply, subsistence, maintenance, munitions, and transportation. In addition, the base is home to the U.S. Army Logistics University and the U.S. Army Transportation School. "The military is a constant feeder to our labor force of educated, highly skilled, highly disciplined people who are ready to go to work," says Held.
On top of that, Virginia is the northernmost right-to-work state on the East Coast, meaning that workers cannot be required to join a labor union in order to be employed, and its Jobs Investment Program provides companies with state-funded grants for job training.
A RECEPTIVE BUSINESS CLIMATE
The jobs training program and right-to-work status reflect the state's business-friendly environment. "It's very easy to do business in Virginia in terms of dealing with elected officials, getting economic incentive packages approved, and getting permits fast-tracked," says JLL's Levy. "Virginia has a very pro-business approach."
The state also offers a competitive tax structure, McClintock says. "We'll never be the lowest, but our taxes will always be consistent," he says. This stability enables companies to accurately forecast their costs from one year to the next, he adds.
Certainly, no state has the perfect business recipe, and Virginia has its share of challenges. Companies struggle with the fierce road congestion in the northern part of the state. Unlike the Port of New York/New Jersey or the Port of Miami, the Port of Virginia lacks proximity to a major consumer base.
Furthermore, Virginia has to compete against the more aggressive incentive packages developed by its southern neighbors. "It's a very competitive market," says Levy. "There are states that will provide very attractive incentives to the point where they will provide free land, they will provide all sorts of tax credits, and they will provide, in some cases, cash and, in a few cases, even build the facility for you." In spite of these challenges, Levy says, Virginia holds its own because of its innate advantages in geographic location, infrastructure, and labor.
"Our population is continuing to grow, and our economy is continuing to grow," says McClintock of the state's Economic Development Partnership. "That shows the environment is still conducive to business and development, and therefore, we are still considered vibrant and relevant."
The New York-based industrial artificial intelligence (AI) provider Augury has raised $75 million for its process optimization tools for manufacturers, in a deal that values the company at more than $1 billion, the firm said today.
According to Augury, its goal is deliver a new generation of AI solutions that provide the accuracy and reliability manufacturers need to make AI a trusted partner in every phase of the manufacturing process.
The “series F” venture capital round was led by Lightrock, with participation from several of Augury’s existing investors; Insight Partners, Eclipse, and Qumra Capital as well as Schneider Electric Ventures and Qualcomm Ventures. In addition to securing the new funding, Augury also said it has added Elan Greenberg as Chief Operating Officer.
“Augury is at the forefront of digitalizing equipment maintenance with AI-driven solutions that enhance cost efficiency, sustainability performance, and energy savings,” Ashish (Ash) Puri, Partner at Lightrock, said in a release. “Their predictive maintenance technology, boasting 99.9% failure detection accuracy and a 5-20x ROI when deployed at scale, significantly reduces downtime and energy consumption for its blue-chip clients globally, offering a compelling value proposition.”
The money supports the firm’s approach of "Hybrid Autonomous Mobile Robotics (Hybrid AMRs)," which integrate the intelligence of "Autonomous Mobile Robots (AMRs)" with the precision and structure of "Automated Guided Vehicles (AGVs)."
According to Anscer, it supports the acceleration to Industry 4.0 by ensuring that its autonomous solutions seamlessly integrate with customers’ existing infrastructures to help transform material handling and warehouse automation.
Leading the new U.S. office will be Mark Messina, who was named this week as Anscer’s Managing Director & CEO, Americas. He has been tasked with leading the firm’s expansion by bringing its automation solutions to industries such as manufacturing, logistics, retail, food & beverage, and third-party logistics (3PL).
Supply chains continue to deal with a growing volume of returns following the holiday peak season, and 2024 was no exception. Recent survey data from product information management technology company Akeneo showed that 65% of shoppers made holiday returns this year, with most reporting that their experience played a large role in their reason for doing so.
The survey—which included information from more than 1,000 U.S. consumers gathered in January—provides insight into the main reasons consumers return products, generational differences in return and online shopping behaviors, and the steadily growing influence that sustainability has on consumers.
Among the results, 62% of consumers said that having more accurate product information upfront would reduce their likelihood of making a return, and 59% said they had made a return specifically because the online product description was misleading or inaccurate.
And when it comes to making those returns, 65% of respondents said they would prefer to return in-store, if possible, followed by 22% who said they prefer to ship products back.
“This indicates that consumers are gravitating toward the most sustainable option by reducing additional shipping,” the survey authors said in a statement announcing the findings, adding that 68% of respondents said they are aware of the environmental impact of returns, and 39% said the environmental impact factors into their decision to make a return or exchange.
The authors also said that investing in the product experience and providing reliable product data can help brands reduce returns, increase loyalty, and provide the best customer experience possible alongside profitability.
When asked what products they return the most, 60% of respondents said clothing items. Sizing issues were the number one reason for those returns (58%) followed by conflicting or lack of customer reviews (35%). In addition, 34% cited misleading product images and 29% pointed to inaccurate product information online as reasons for returning items.
More than 60% of respondents said that having more reliable information would reduce the likelihood of making a return.
“Whether customers are shopping directly from a brand website or on the hundreds of e-commerce marketplaces available today [such as Amazon, Walmart, etc.] the product experience must remain consistent, complete and accurate to instill brand trust and loyalty,” the authors said.
When you get the chance to automate your distribution center, take it.
That's exactly what leaders at interior design house
Thibaut Design did when they relocated operations from two New Jersey distribution centers (DCs) into a single facility in Charlotte, North Carolina, in 2019. Moving to an "empty shell of a building," as Thibaut's Michael Fechter describes it, was the perfect time to switch from a manual picking system to an automated one—in this case, one that would be driven by voice-directed technology.
"We were 100% paper-based picking in New Jersey," Fechter, the company's vice president of distribution and technology, explained in a
case study published by Voxware last year. "We knew there was a need for automation, and when we moved to Charlotte, we wanted to implement that technology."
Fechter cites Voxware's promise of simple and easy integration, configuration, use, and training as some of the key reasons Thibaut's leaders chose the system. Since implementing the voice technology, the company has streamlined its fulfillment process and can onboard and cross-train warehouse employees in a fraction of the time it used to take back in New Jersey.
And the results speak for themselves.
"We've seen incredible gains [from a] productivity standpoint," Fechter reports. "A 50% increase from pre-implementation to today."
THE NEED FOR SPEED
Thibaut was founded in 1886 and is the oldest operating wallpaper company in the United States, according to Fechter. The company works with a global network of designers, shipping samples of wallpaper and fabrics around the world.
For the design house's warehouse associates, picking, packing, and shipping thousands of samples every day was a cumbersome, labor-intensive process—and one that was prone to inaccuracy. With its paper-based picking system, mispicks were common—Fechter cites a 2% to 5% mispick rate—which necessitated stationing an extra associate at each pack station to check that orders were accurate before they left the facility.
All that has changed since implementing Voxware's Voice Management Suite (VMS) at the Charlotte DC. The system automates the workflow and guides associates through the picking process via a headset, using voice commands. The hands-free, eyes-free solution allows workers to focus on locating and selecting the right item, with no paper-based lists to check or written instructions to follow.
Thibaut also uses the tech provider's analytics tool, VoxPilot, to monitor work progress, check orders, and keep track of incoming work—managers can see what orders are open, what's in process, and what's completed for the day, for example. And it uses VoxTempo, the system's natural language voice recognition (NLVR) solution, to streamline training. The intuitive app whittles training time down to minutes and gets associates up and working fast—and Thibaut hitting minimum productivity targets within hours, according to Fechter.
EXPECTED RESULTS REALIZED
Key benefits of the project include a reduction in mispicks—which have dropped to zero—and the elimination of those extra quality-control measures Thibaut needed in the New Jersey DCs.
"We've gotten to the point where we don't even measure mispicks today—because there are none," Fechter said in the case study. "Having an extra person at a pack station to [check] every order before we pack [it]—that's been eliminated. Not only is the pick right the first time, but [the order] also gets packed and shipped faster than ever before."
The system has increased inventory accuracy as well. According to Fechter, it's now "well over 99.9%."
IT projects can be daunting, especially when the project involves upgrading a warehouse management system (WMS) to support an expansive network of warehousing and logistics facilities. Global third-party logistics service provider (3PL) CJ Logistics experienced this first-hand recently, embarking on a WMS selection process that would both upgrade performance and enhance security for its U.S. business network.
The company was operating on three different platforms across more than 35 warehouse facilities and wanted to pare that down to help standardize operations, optimize costs, and make it easier to scale the business, according to CIO Sean Moore.
Moore and his team started the WMS selection process in late 2023, working with supply chain consulting firm Alpine Supply Chain Solutions to identify challenges, needs, and goals, and then to select and implement the new WMS. Roughly a year later, the 3PL was up and running on a system from Körber Supply Chain—and planning for growth.
SECURING A NEW SOLUTION
Leaders from both companies explain that a robust WMS is crucial for a 3PL's success, as it acts as a centralized platform that allows seamless coordination of activities such as inventory management, order fulfillment, and transportation planning. The right solution allows the company to optimize warehouse operations by automating tasks, managing inventory levels, and ensuring efficient space utilization while helping to boost order processing volumes, reduce errors, and cut operational costs.
CJ Logistics had another key criterion: ensuring data security for its wide and varied array of clients, many of whom rely on the 3PL to fill e-commerce orders for consumers. Those clients wanted assurance that consumers' personally identifying information—including names, addresses, and phone numbers—was protected against cybersecurity breeches when flowing through the 3PL's system. For CJ Logistics, that meant finding a WMS provider whose software was certified to the appropriate security standards.
"That's becoming [an assurance] that our customers want to see," Moore explains, adding that many customers wanted to know that CJ Logistics' systems were SOC 2 compliant, meaning they had met a standard developed by the American Institute of CPAs for protecting sensitive customer data from unauthorized access, security incidents, and other vulnerabilities. "Everybody wants that level of security. So you want to make sure the system is secure … and not susceptible to ransomware.
"It was a critical requirement for us."
That security requirement was a key consideration during all phases of the WMS selection process, according to Michael Wohlwend, managing principal at Alpine Supply Chain Solutions.
"It was in the RFP [request for proposal], then in demo, [and] then once we got to the vendor of choice, we had a deep-dive discovery call to understand what [security] they have in place and their plan moving forward," he explains.
Ultimately, CJ Logistics implemented Körber's Warehouse Advantage, a cloud-based system designed for multiclient operations that supports all of the 3PL's needs, including its security requirements.
GOING LIVE
When it came time to implement the software, Moore and his team chose to start with a brand-new cold chain facility that the 3PL was building in Gainesville, Georgia. The 270,000-square-foot facility opened this past November and immediately went live running on the Körber WMS.
Moore and Wohlwend explain that both the nature of the cold chain business and the greenfield construction made the facility the perfect place to launch the new software: CJ Logistics would be adding customers at a staggered rate, expanding its cold storage presence in the Southeast and capitalizing on the location's proximity to major highways and railways. The facility is also adjacent to the future Northeast Georgia Inland Port, which will provide a direct link to the Port of Savannah.
"We signed a 15-year lease for the building," Moore says. "When you sign a long-term lease … you want your future-state software in place. That was one of the key [reasons] we started there.
"Also, this facility was going to bring on one customer after another at a metered rate. So [there was] some risk reduction as well."
Wohlwend adds: "The facility plus risk reduction plus the new business [element]—all made it a good starting point."
The early benefits of the WMS include ease of use and easy onboarding of clients, according to Moore, who says the plan is to convert additional CJ Logistics facilities to the new system in 2025.
"The software is very easy to use … our employees are saying they really like the user interface and that you can find information very easily," Moore says, touting the partnership with Alpine and Körber as key to making the project a success. "We are on deck to add at least four facilities at a minimum [this year]."