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Conveyor Sortation Systems

State-of-the-art conveyor sorting systems, where speed meets precision

Conveyor sortation systems are pivotal components in modern warehouse automation strategies, streamlining the process of sorting and directing products efficiently through a facility. These systems leverage a variety of conveyor sorting technologies alongside barcode scanning hardware and sophisticated warehouse management system (WMS) software. Together, these elements work to automate the routing of products within a warehouse, reducing manual labour and increasing accuracy and throughput.

At its most basic, a conveyor sortation system can direct totes, boxes, or bags—referred to as load units—in a few predetermined directions. The direction is typically determined by the contents of the load unit and the rules established within the host software system.

As the complexity of a warehouse operations increases, so does the complexity of the conveyor sortation systems. In more advanced setups, load units can be routed to a multitude of destinations. A prime example of this is carrier sortation in logistics operations, where orders are distributed among various carriers and carrier services to ensure timely and cost-effective delivery. This multi-destination routing is crucial for operations that handle a diverse range of products or serve a wide geographical area.

The type of load unit significantly influences the choice of conveyor technology. For instance, items in boxes and totes would easily travel on roller conveyor type systems, while light items in ploy-bags would need belt type conveying solutions, as they would typically not convey on rollers. Additionally, the throughput—how many load units need to be sorted within a given time frame—is a critical factor in selecting the right conveyor technology. High-throughput environments would necessitate faster, more advanced systems to keep up with the demand.

These systems can vary greatly in terms of sophistication and cost, from simple pop up transfers and swivel-wheel diverts, to complex high-speed sorters utilising tilt-trays, cross-belts, or sliding shoe sorting technology. The choice depends on various factors including the nature of the items being sorted, the required speed of operation, and the specific needs of the warehouse or distribution centre.

Key Features

When considering a conveyor sorting system for a warehouse or distribution centre, several key features play a crucial role in its efficiency, reliability, and suitability for specific tasks. Here are 10 key features to look for:

  1. Sortation Speed: The ability of the system to sort a high number of items per minute. Higher speeds are essential for operations with a high throughput demand.
  2. Accuracy: The system’s ability to correctly sort items to their designated destinations. High accuracy reduces errors and improves overall efficiency.
  3. Flexibility: The ability to handle a variety of item sizes, shapes, and weights. A flexible system can adapt to different types of products without requiring significant changes.
  4. Scalability: The capability to expand or upgrade the system as the business grows or as needs change. Scalable systems can accommodate increased volume or additional sorting destinations.
  5. Integration Capability: The system should easily integrate with existing Warehouse Management Systems (WMS) and other automation software to ensure seamless operation and real-time tracking.
  6. Type of Sortation Technology: The specific technology used (e.g., pop-up belt transfer, swivel wheel divert, activated roller belt, tilt-tray, cross-belt, sliding shoe sorter, etc.) should match the particular needs of the operation considering factors like item type and required speed.
  7. Energy Efficiency: Systems designed to use less energy can reduce operational costs and are better for the environment.
  8. Reliability and Durability: The system should be made of high-quality materials and designed to withstand the operational demands to minimise downtime and maintenance costs.
  9. Safety Features: Essential for protecting workers and products, features might include emergency stop buttons, fixed guards, light curtains, safety fencing, etc.
  10. Ease of Maintenance: The system should be designed for easy access to critical components for regular maintenance and quick repairs, reducing downtime and maintenance costs.

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