Wireless that was ready on day one: a 460,000 square foot distribution center for Zinus
With two weeks to design and deploy, Katalyst built the wireless backbone for Zinus's new Summerville, South Carolina distribution center so it supported full operations from the go-live date, then stayed on to manage it.
About Zinus
Zinus is a pioneer in comfort innovation. Its patented compressed and rolled mattresses were among the first on the market more than 20 years ago, and the company has since shipped millions of mattresses and beds through major distributors including Amazon, Wayfair, Target, Sam's Club, and Walmart. With production in its own factory in Xiamen, China and corporate offices in Seoul, Korea, Zinus runs its U.S. corporate operations and distribution out of Northern California. Rapidly expanding, the company secured 460,000 square feet of warehouse and office space in Summerville, South Carolina for a new U.S. distribution center.
The Challenge
Zinus had a two-week window to design, configure, and deploy a wireless infrastructure across the entire 460,000 square foot facility, and needed a partner that could execute quickly and accurately. The network had to support full operations on the specified go-live date without any disruption. In a high-volume distribution environment, coverage gaps or dropped connections are not an inconvenience, they stop the business.
The Solution
Katalyst conducted a thorough wireless survey of the entire warehouse across multiple site visits, then delivered a design built on best-in-class technology to meet Zinus's performance requirements. The deployment included 47 Cisco Meraki ruggedized dual-band wireless access points, placed for optimal coverage both inside the facility and outside across the loading dock and freight container area. Five Cisco Meraki PoE switches powered the access points and provided Layer 3 routing across multiple networks, cloud-managed visibility and control down to the port level, and monitoring of every connected endpoint. The build also ran 5,800 feet of copper and fiber optic cabling throughout the warehouse. Ongoing infrastructure managed services keep the environment performing through proactive monitoring, maintenance, and remediation.
"I chose this team because they spent a lot of time on site understanding our infrastructure before winning the project. I wanted a partner that actually cares about what they do, and it was clear they are not just about selling services and moving on. I cannot tell you how much peace it gives me knowing they will handle anything that comes along."
Head of Logistics and Supply Chain Operations, ZinusThe Results
Zinus has a solid, high-performing wireless infrastructure that supports the demands of daily operations, including continuous connectivity for 100 handheld scanners across the facility campus. With infrastructure managed services in place, issues are caught and resolved before they affect operations. The deployment delivered such strong results that Zinus planned to replicate the same wireless design at its Northern California distribution center.
Key Takeaways
- Ready on the go-live date. A full 460,000 square foot wireless build, designed and deployed in two weeks.
- Coverage where the work happens. 47 ruggedized access points reaching the warehouse floor, loading docks, and freight containers.
- Operations that do not drop. 100 handheld scanners stay connected across the campus.
- A model worth repeating. Results strong enough that Zinus planned the same approach for another distribution center.
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