Sortation Systems
Increase throughput, accuracy and scalability with automated sorting
Sortation systems, also known as sorters, are material handling solutions that can automatically group items by predetermined criteria. They can be used in warehouses, factories, distribution centres and fulfilment centres to sort totes, trays, cartons, polybag and paper bags.
Sorters reduce manual handling to organise incoming and outgoing goods at high speeds, increasing throughput. Their versatility and scalability make them ideal for managing growing product demand and busy periods such as peak seasons.
Core Components of Sortation Systems
Conveyor Systems and Infeeds
Goods are inducted manually or automatically via infeeds and transported between work areas on a straight or continuous-loop conveyor. Loop designs allow items to recirculate if destinations are temporarily full, maintaining continuous flow.
Barcode Scanners
Integrated barcode scanners identify each item as it travels through the sorter, enabling the control system to assign the correct destination based on set criteria.
Diverters and Outfeeds
Diverters such as cross-belts, pushers or swivel wheels separate and route items accurately to outfeeds, where goods accumulate in chutes or cages.
How a Sortation System Works
A sortation system automatically identifies, routes and distributes items to the correct destination in a continuous flow:
- Induction and Conveying – Items are inducted manually or automatically and transported through the system via conveyor system.
- Identification – A barcode scanner identifies each item and link it to order and destination data.
- Diverting – The sorter redirects items to the correct destination using a diverting mechanism, such as a cross-belt.
- Accumulation – Sorted items are buffered and accumulated at the destination for packing, palletising or dispatch.
Applications of Sortation Systems
- Inbound sorting – by receiving area, storage zone or quality check
- Outbound sorting – by order postcode, store location or assigned courier service
- Internal sorting – by internal destination, product type or value-added service
- Returns sorting – by resale, refurbishment, quarantine, disposal or supplier return
- Exception sorting – unidentified items, damaged goods or system errors
- Consolidation sorting – grouping items by order, store, pallet or shipment
- Sequencing sorting – defined order for production, loading or delivery
Types of Sortation Systems
Different sortation technologies are used depending on throughput, item characteristics and layout requirements.
GEBHARDT SpeedSorter® loop at flaconi
In autumn 2020, GEBHARDT Intralogistics Group received an order to implement packet conveying and unit sortation at the online beauty pure player flaconi. The highlight of the new logistics centre is the connection of the new GEBHARDT SpeedSorter® loop to the warehouse control system, including the PLC control. In just nine months, the fast-growing retailer can now flexibly and quickly respond to customer-related orders on an area covering 28,000m2 at the Halle location.