Warehouse Formats - Large FC, Medium FC & Dark Stores

Frequently Asked Questions

How do I choose between a large FC, medium FC, and dark store?

The choice depends on your order volume, delivery speed requirements, and channel mix. Large Format FCs (50K-500K+ sq ft) suit enterprise brands with high SKU counts and national distribution needs. Medium Format FCs (10K-50K sq ft) are ideal for growing D2C brands fulfilling marketplace and website orders. Dark Stores (1K-5K sq ft) are hyperlocal micro-fulfilment centres for Quick Commerce - 10-minute to 2-hour delivery within a city. Prozo's team analyses your data and recommends the right format, and many brands use a combination of all three.

Can I use multiple warehouse formats simultaneously?

Absolutely. Many Prozo clients operate a hub-and-spoke model: a large FC serves as the central distribution hub, medium FCs handle regional marketplace and D2C fulfilment, and dark stores enable hyperlocal Quick Commerce delivery. ProWMS and ProOMS unify inventory and order management across all formats, and Control Tower provides a single dashboard view of every facility in your network.

What technology stack runs across all warehouse formats?

Every Prozo facility - regardless of format - runs on the same technology stack: ProWMS for warehouse management, ProOMS for order orchestration, ProSHIP for carrier selection and shipping, and Control Tower for real-time visibility and exception management. This unified stack means you get consistent SLAs, reporting, and operational standards whether your order ships from a 500K sq ft mega-FC or a 2K sq ft dark store.

What is a hub-and-spoke warehouse model and how does Prozo implement it?

A hub-and-spoke model positions a large central fulfilment centre (hub) for bulk storage and national distribution, with smaller regional facilities (spokes) closer to demand clusters for faster last-mile delivery. Prozo implements this by combining large FCs as hubs with medium FCs and dark stores as spokes, all connected through ProWMS and ProOMS. Inventory flows from hub to spokes based on demand forecasts, and orders are routed to the nearest spoke with available stock.

How does Prozo determine which warehouse format is right for my brand?

Prozo's solutions team analyses your historical order data, SKU catalogue size, channel mix, delivery speed requirements, and geographic demand patterns to recommend the optimal format. Brands with 50,000+ orders per day and national distribution typically need large FCs. Growing D2C brands processing 500-5,000 orders per day fit medium FCs. Brands selling on Blinkit, Zepto, or Swiggy Instamart need dark stores. Many brands use a combination of formats as they scale.

What is the difference between a dark store and a micro-fulfilment centre?

A dark store is a small (1K-5K sq ft) facility that functions like a retail store but serves only online orders - no walk-in customers. A micro-fulfilment centre (MFC) is a similar concept but may be embedded within an existing retail store or warehouse. In Prozo's context, both terms refer to hyperlocal fulfilment nodes designed for quick commerce delivery in 10 minutes to 2 hours. They operate with tight SKU assortments and rapid pick-pack cycles optimized for speed.

Can I start with a small warehouse format and upgrade later?

Yes. Prozo's warehouse formats are designed for progressive scaling. A brand can start with shared space in a medium FC, graduate to a dedicated medium FC as volumes grow, and eventually move to a large FC for national distribution. Adding dark stores for quick commerce can happen at any stage. Because all formats run on the same ProWMS and ProOMS stack, migrations involve zero re-integration effort and no disruption to live order processing.

How many warehouse locations does Prozo operate across India?

Prozo operates 50+ warehouse locations across India spanning metros and Tier-1 cities including Delhi-NCR, Mumbai, Bangalore, Hyderabad, Chennai, Kolkata, Pune, Ahmedabad, Jaipur, and Lucknow. The network totals approximately 3 million square feet of fulfilment space across large FCs, medium FCs, and dark stores. New locations are added regularly based on client demand and quick commerce expansion requirements.

What order volumes can each warehouse format handle?

Large FCs (50K-500K+ sq ft) can process 50,000 to 500,000+ orders per day depending on configuration and staffing. Medium FCs (10K-50K sq ft) typically handle 500 to 50,000 orders per day. Dark stores (1K-5K sq ft) process 200 to 2,000 orders per day with rapid turnaround. These are typical ranges - actual capacity depends on SKU complexity, average items per order, and VAS requirements. Prozo right-sizes each facility to match the brand's throughput needs.

Does Prozo offer automation-ready warehouse formats?

Yes. Prozo's large FC format supports automation infrastructure including conveyor systems, automated sorting, put-to-light and pick-to-light systems, and robotic pick-assist solutions. Automation readiness is built into the facility design with appropriate floor loading, power supply, and network infrastructure. For brands with volumes that justify automation investment, Prozo designs the facility layout and technology configuration to maximize throughput while reducing per-order processing costs.