Project Scope & Challenge
Dexion Liverpool, the Australian OPEX integrator, needed a local partner to manufacture the specialised totes used in OPEX Perfect Pick automated storage and retrieval systems (AS/RS).
Perfect Pick is a goods-to-person solution that uses fleets of iBOT® robots to move totes through high-density racking and deliver them to operators for fast, accurate order fulfilment. Every tote must meet strict tolerances for flatness, dimensional accuracy, and durability — even small variances can affect how the iBOTs handle, store, and retrieve them.
Historically, these totes were manufactured in the United States. But because they are non-nestable, international shipping was inefficient and costly. Dexion Liverpool sought a solution that was local, cost-effective, and dependable — and that could be delivered under tight timeframes.
The project carried tight commercial deadlines and high technical expectations. Delivering a localised version of such a specialised product would require precision engineering, careful material selection, and seamless coordination across multiple stakeholders.
Design & Development
Holloway Group’s engineering team managed the project end-to-end, from reverse-engineering the totes through to tooling, testing, and production. This began with 3D scanning validation of physical samples to confirm every critical dimension and tolerance before mould design.
At 14.8 tonnes, it was one of the largest moulds ever put into operation at Holloway Group’s Minto facility, demonstrating the team’s ability to manage large-scale tooling in local production.
Key innovations included:
- An innovative ejection system that synchronised multiple side movements to release the part cleanly despite minimal draft angles
- Complex cooling channels with beryllium copper inserts in rib sections to control heat and maintain flatness
- Specialised air vents positioned at final fill points to ensure smooth material flow and consistent cavity filling
Because the original U.S. resin grade was unavailable locally, multiple alternatives were tested before selecting a material that matched shrinkage behaviour while delivering strength and consistency.
The result was a tool that balanced precision, durability, and efficiency — enabling consistent production of totes that met the strict requirements of the OPEX Perfect Pick system.
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Testing & Collaboration
The first mould trials were undertaken in OPEX USA machines, confirming the totes could operate within the Perfect Pick environment. Further testing identified refinements needed to consistently meet tolerance requirements.
Holloway Group then implemented tooling and design adjustments, focusing on cooling and venting, before shipping the revised totes for final validation at the end customer’s Sydney site. Here, the totes integrated seamlessly into the live system.
Close partnership with Dexion Liverpool was central throughout. Working across three countries, Holloway Group and Dexion aligned on results, design changes, and deadlines — ensuring the project moved smoothly from trial through to validated production.
Production & Delivery
Once validated, production scaled rapidly. In just one week of manufacturing at Minto, Holloway Group produced 5,000 totes to meet the project’s immediate requirements. Logistics were carefully managed, with daily pickups coordinated with Dexion Liverpool to ensure a steady flow into their customer’s OPEX Perfect Pick machines.
Local production now provides Dexion Liverpool with a reliable and scalable source of totes, manufactured close to where they are needed.
Outcome & Customer Impact
For Dexion Liverpool and their customer, the benefits were clear:
- Cost savings by eliminating inefficient imports
- Reliable local supply to support ongoing and future projects
- Performance assurance with every tote meeting tight tolerance requirements for seamless iBOT handling
- Future scalability with a dedicated Australian mould supporting further rollouts planned for 2026 and beyond
“Having the totes produced locally has given us greater confidence in supply, quality, and speed to market. Partnering with Holloway Group has enabled us to deliver a strong outcome for our customer and sets us up well for future projects.”
— Graham Urquhart, Director, Dexion Liverpool
Looking Ahead
For Holloway Group, this project was more than a technical milestone. It reinforced the ability to take on complex engineering challenges and deliver solutions that create measurable value for customers. By localising production of OPEX Perfect Pick totes, Holloway Group demonstrated how Australian manufacturing can meet global standards while giving customers the advantage of speed, reliability, and scalability.
Looking ahead, this project sets the foundation for supporting future automation and supply chain initiatives in Australia — where local manufacturing capability will be increasingly critical to resilience and growth.