Aug. 26, 2024
Machinery
Sortation System by Application
Sortation systems can be used to help with various aspects of order fulfillment. For instance, there are sortation systems designed to automate receiving, picking and packing, and shipping.
Leveraging an automated sortation system during the receiving process can help you better process your inventory as it enters the warehouse, increasing visibility into your inventory levels. Sortation systems can help with the following receiving applications.
: Return items can be identified and sent to specific stations designed to handle returns or exchanges based on your company&#;s protocols. Once the items are processed, the sortation system can automatically divert them to the appropriate station for destruction, put away, or used to fill an open order.
A receiving system can efficiently sort a high volume of product units or cases and transport them to the optimal location for storage.
Sortation systems can also be utilized to sort inbound items that are being unloaded and loaded directly into outbound delivery. The accurate intake and speedy reorganization of products increases the efficiency of these outbound deliveries.
When selecting sortation equipment for receiving in your warehouse, consider the number of inbound trailers that need to be unloaded and processed at the same time, as well as the total number of destinations needed for putaway or other processing. Identifying these parameters will help you select the best option for your warehouse.
Within order fulfillment, picking and packing are the most labor-intensive processes. When picking and packing are done manually, workers have to walk long distances throughout warehouses, manually pick items, bring them to the correct station, and pack them into orders for shipping. Warehouses are large facilities, and walking to and from inventory stations can be time-consuming. Not to mention, manually picking and packing orders is a slow and tedious process that can easily be messed up due to human error.
Sortation systems streamline picking and packing, managing more orders quickly and accurately. There are semi-automatic sortation systems designed to help workers facilitate picking and packing, as well as more advanced options that handle the majority of the picking and packing processes. The type of system you need depends on the size of your workforce, the number and type of packing stations required, as well as the case or palette sizes and weights. We&#;ll help you identify the best options later in the post.
Sortation systems are a key driver of shipping efficiency, decreasing order turnaround time and improving customer satisfaction. An advanced sortation system enables orders to skip parcel hubs, which is known as zone skipping. That&#;s because sortation systems can presort groups of orders in an optimal format. This also allows for lower shipping costs and more orders to be processed within shorter timelines. Sortation systems can be used to presort orders in a variety of ways depending on the item size and weight, the volume of shipping, and the number of pallet build locations or trailers that will be used at the same time.
Now that you understand the applications of sortation equipment, let&#;s review the types of sortation systems that can be used for different types of inventory.
The distinction between a unit and a case is important when talking about sortation systems because they generally require different types of equipment. In warehouse management, an inventory unit is the language used to describe the smallest unit of an item. All other inventory measurements can be split into multiple parts, including a case. For example, a case is a box that contains numerous inventory units, and the size of the case can vary based on the unit size and logistics. Likewise, there is a case sorter that is designed to handle cases, and there is a unit sorter designed to manage individual units. The exception to this is when a hybrid model is used that can accommodate both units and cases.
Read on to learn specific examples of case sorters, unit sorters, and hybrid case and unit sorters.
Case sorters are designed to receive, sort, and transport entire cases, cartons, or totes within a warehouse. Examples of case sorters include the following:
A Pop-Up Sorter consists of wheels or rollers emerging from a conveyor belt which pop up to transfer items to another downstream conveyor. This type of case sorter has medium to high throughput and can handle 40-100 cases per minute. Pop-up Sorters work well for packing applications.
A
Carton Sortation Conveyor
is a belt-powered pop-up wheel conveyor with high throughput and can sort up to 100 cartons per minute. It automatically diverts cases to a specific destination and can also divert cartons to shipping doors.
A Pivoting Arm Sorter uses a series of paddles that divert and sort cases from a primary conveyor onto a secondary conveyor. It has medium to high throughput and can handle 50-100 cases per minute. A Pivoting Arm Sorter is commonly used for shipping applications.
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Featured content:A Pusher Sorter uses pneumatic pushers mounted to a conveyor belt. These pushers extend at specific angles to divert a case onto a secondary conveyor. This sorter has the lowest throughput and can process only 10-30 cartons a minute.
Unit sorters are designed to handle inventory units of varying sizes and shapes. Examples of unit sorters include the following:
Raymond West supplies a full range of conveyor and automation products, including all types of sortation solutions. To speak with a Raymond automation expert, us at (253) 333-.
Are you considering a sortation system for your local warehouse, distribution center or production facility? The most common kinds of sortation systems vary widely in capability and cost. In this article we provide a high level overview of the benefits and shortcomings of the three most prominent kinds of sortation systems.
Cross-belt and tilt-tray sortation systems deliver similar functionality and are oftentimes associated when talking about sortation automation. However, they are very different mechanisms.
Tilt-tray sorters are a series of trays attached to carts that are transported on a continuous-loop conveyor. Items are added to the trays at one or more induction stations on the loop via manual or automatic procedures. When a product reaches its sorting location, the tray that is transferring it tilts and transfers the product onto a chute.
Cross-belt sorters are motorized belt conveyors mounted to carts running on a continuous conveyor loop. Similar to tilt-trays, cross-belt sorters move materials onto a chute when they reach the appropriate sorting location.
Advantages: Tilt-tray and Cross-belt sorters provide the best sorting rate and can manage a wide array of product types when compared to other sortation solutions. They are a great alternative for operations that manage a variety of SKUs. These kinds of systems are likewise fairly quiet and enable a more comfortable workplace for warehouse personnel.
Disadvantages: The speed, capacity and versatility or these sorters come at a price-- they are among the most costly sortation solutions offered.
Sliding shoe sorters utilize a "shoe" system attached to the conveyor surface that moves and diverts materials onto a secondary, after-sort conveyor. Shoe sorter solutions receive goods from a unified stream of items that may be a consolidated feed from numerous upstream areas of a facility. These kinds of sortation systems are widely utilized in shipping applications.
Advantages: Sliding shoe sorter equipment setups enable a relatively high peak rate, sometimes several hundred items per minute, depending upon the product size and weight. Additionally, a vast array of products can be handled due to the simplicity and versatility of a positive divert system.
Disadvantages: Shoe sorters are more expensive than other options like pop-up wheel sorters. Also, divert centers are not readily movable, making the system challenging and costly to rearrange. These systems often generate more noise than tray or belt systems and are therefore not as worker compatible as other kinds of sorters.
Pop-up wheel sorters are an attractive alternative because they are fairly affordable and easy to implement. Wheels or rollers are incorporated into a belt conveyor. When an item must be diverted, the wheels pop up to divert items at an angle to an alternate, downstream conveyor.
Advantages: Pop-up wheel sorters are adaptive, so components can be rapidly added or eliminated when the line needs modification. These systems can also be substantially less expensive than other sorter choices.
Disadvantages: These kinds of sorters offer significantly less speed and capability than shoe, cross-belt or tilt-tray options. They will certainly increase efficiency, but might not multiply total output like other alternatives. Due to the fact that pop-up systems don't offer a positive divert, the types of products they can process are reduced.
If you'd like more information on sortation alternatives, call an automation professional at Raymond West today!
Raymond's Seattle service operation includes most of Western Washington, including Seattle, Bellevue, Kirkland, Redmond, Bothell, Woodinville, Lynnwood, Everett, Tukwila, Renton, SeaTac, Burien, Kent, Federal Way, Fife, Sumner, Auburn, Tacoma, Lakewood, Puyallup, Olympia, Lacey and surrounding areas.
Raymond West | Seattle Material Handling Equipment Supplier
S 287th St
Auburn, WA
(253) 333-
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