CASE STUDY:  

Decentralized Motion Solution

Inside ThredUp’s High-Tech Transformation of Its Four-Story Conveyor System

ThredUp — one of the world’s largest online resale platforms for women’s and children’s apparel — depends on a highly efficient and reliable conveyor system to ensure timely, accurate order fulfillment. However, recurring failures within its automated chain drive operations were causing costly downtime and disrupting performance.

By partnering with SEW-EURODRIVE, ThredUp implemented a precision-engineered, decentralized motion solution that eliminated sensor failures, prevented mechanical jams, and restored reliable, continuous operation across its four-story automated system.

Challenge:

Inaccurate Positioning, Mounting Failures, And Wasted Downtime

ThredUp’s four-story overhead chain conveyor moves thousands of garments daily, but its basic VFD controls, proximity sensors, and problematic chain-count tracking led to frequent sensor misreads, sequencing errors, and complex wiring. Falling garments jammed catenary drives, and each chain break caused up to 12 hours of downtime — halting fulfillment and costing thousands in missed revenue. This legacy approach created several critical pain points:

  • Imprecise control: Sensor miscounts from misaligned chains delivered the wrong garments for processing.
  • Excessive wiring: Multiple sensors per chain required large floor-mounted cabinets and expensive wire runs.
  • Manual resets: 600+ chains required time consuming re-zeroing after power loss.
  • Frequent failures: Fallen garments caused jams and structural damage, resulting in critical downtime.
  • Limited scalability: Cabinet and wiring demands restricted expansion.
  • The customer needed a smarter, safer, and more scalable system. 

Solution:

Intelligent Motion with Zero Guesswork

SEW-EURODRIVE partnered with ThredUp to deliver a fully decentralized, precision-controlled solution using MOVIGEAR® Performance mechatronic drives with integrated absolute encoders and MOVIKIT® Positioning software.

Key Solution Features:

  • Absolute encoder feedback: Eliminated proximity sensors; new drives retain exact position — even after power loss.
  • MODULO positioning: Used MOVIKIT® logic to divide continuous motion into precise virtual frames.
  • Decentralized architecture: Eliminated large control cabinets; power and Ethernet daisy-chained between drives.
  • Condition monitoring: Real-time speed and torque monitoring to prevent damage.
  • Quieter operation: MOVIGEAR IE5 units significantly reduced noise.
  • Energy efficient: High-efficiency drives supported sustainability goals.
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360 MOVIGEAR Performance drives installed on ThredUp’s overhead garment conveyor lines

Results:

Scalable Automation. Zero Downtime. Total Confidence. 

The implementation of 360 MOVIGEAR Performance drives on ThredUp’s overhead conveyor lines improved their automation processes.

  • Pinpoint Accuracy: Garment retrieval positioning now accurate to within 1/100th of a frame
  • System Uptime: Zero unexpected downtime due to jams or sensor loss
  • Simplified Design: No more referencing routines or cabinet-based wiring nightmares
  • Scalable Framework: SEW-EURODRIVE’s MOVI-C modular automation platform scales easily
  • Operational Safety: Chain-jam shutdowns now occur automatically within milliseconds and keep production moving, and damage to near zero.
  • Quieter Facilities: Operator feedback confirms a more comfortable work environment

"SEW didn’t just solve a problem—they transformed our entire chain delivery system. We gained accuracy, safety, scalability, and peace of mind."
—  Keith Hiyama, VP of Automation and Industrial Engineering, ThredUp

 

Why it matters

SEW-EURODRIVE Solves What Others Can’t
ThredUp’s original request was simple: improve positioning. But SEW-EURODRIVE delivered much more.

Our modular MOVIGEAR Performance system didn’t just fix the old problem — it eliminated an entire class of future failures. From absolute accuracy to predictive protection, SEW-EURODRIVE built ThredUp a smarter, cleaner, more resilient motion solution that no one else could provide.

“We didn’t just replace gearboxes—we future-proofed the system.” 
—  Mike Demeo, National Business Development Engineer - Drives & Automation,  SEW-EURODRIVE-USA

 

Application Summary:

Application Areas:

  • Overhead garment conveyor system
    (automated chain drive)  
  • Original System:
    1 HP motor with Cabinet-mounted Drive  

SEW-EURODRIVE Product(s):

  •  MOVIGEAR Performance
    MGFAS4-DFC-C/DI/AZIZ/DSP/PE/PG/BW1 

    Size 2 MOVIGEAR
    Encoder Absolute AZ1Z
    Ratio 36.61 | Speed 2000 rpm
    Fieldbus Ethernet IP
    DynaStop holding brake
    MOVIKIT Positioning (Modulo)

CUSTOMER:

ThredUp Inc. / Dallas, TX

INDUSTRY:

Fashion Resale / e-commerce Logistics

APPLICATION:

Overhead garment conveyor system 
 (automated chain drive) 

PREVIOUS TECHNOLOGY:

1 HP motor with Cabinet-mounted Drive  

Basic VFD controls, proximity sensors, and chain-count tracking 

SOLUTION:

MOVIGEAR Performance
    MGFAS4-DFC-C/DI/AZIZ/DSP/PE/PG/BW1

MOVIKIT Positioning

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About SEW-EURODRIVE

Founded in 1931 in Bruchsal, Germany, SEW-EURODRIVE is a global leader in Industrial Automation, with operations in over 50 countries, 17 manufacturing plants, 92 assembly facilities, and more than 21,000 employees. The company holds over 1,000 patents, continuously driving technological advancements in gearmotors, frequency inverters, servo drives, and Industry 4.0 solutions.

SEW-EURODRIVE provides engineered solutions in countless industries, including automotive, food & beverage, pharmaceuticals, mining, steel, logistics, energy, and more, providing customized automation solutions that enhance efficiency, productivity, and sustainability. Despite its global reach, SEW-EURODRIVE remains family-owned, ensuring long-term vision, strong values, and a commitment to excellence.

SEW-EURODRIVE. Driving the World™

SEW-EURODRIVE, Inc.
220 Finch Road
Wellford, SC 29385
(P): (864) 439-7537
cslyman@seweurodrive.com
www.seweurodrive.com 

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