Automated Sortation Systems [Types, Application & Benefits]

Every second counts in a busy warehouse.

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As order volumes grow and delivery expectations tighten, the ability to sort thousands of items accurately and efficiently is no longer a nice-to-have—it’s a necessity. That’s where automated sortation systems come in.

These automated material handling solutions identify, route, and direct items based on destination, size, weight or other criteria, further reducing manual labor and minimizing errors along the way.

Using a combination of conveyors, chutes, diverter,s and robotic arms, they help optimize warehouse operations and improve overall order processing speed.

In this guide, we’ll explore:

• The main types of sortation systems
• Their key benefits
• Their common applications across different industries

3 Types of Sortation Systems and How They Function

A sortation system integrates different technologies designed to sort large volumes of inventory with efficiency and speed.

Here’s how they operate:

Linear Sortation Systems

Linear sortation systems employ conveyor systems where items travel along a linear path.

These systems incorporate mechanisms like pop-up wheels or arms to divert items to the left or right into sorting bins or additional conveyors, based on automated decisions.

• Best for: Medium-speed applications, simple layouts, limited space
• Common technologies: Pop-up wheel sorters, pusher sorters

Pusher Sortation Systems

They feature a simple conveyor setup with a series of pusher arms spaced along the path. These arms extend to transfer items from the main conveyor to a secondary location as directed by the automation system.

• Best for: Flat, lightweight items or for lower throughput environments.
• Strength: Simple, cost-effective, and easy to maintain

Loop Sortation Systems

They consist of conveyors arranged in a continuous loop. Ideal for operations using tilt-tray and cross-belt sorters.

In these systems, items are placed on trays or belts that circulate around the loop. At designed points, trays or belts adjust their orientation or activate to direct the item into a designated chute, tote or bin.

• Best for: High-speed, high-volume environments with many sorting destinations
• Common in: E-commerce, retail, large distribution centers

The Importance of Sortation Systems in Warehouse Automation

Automated sortation is the process of identifying items on a conveyor belt or other transport mechanism and diverting them to various destinations within a warehouse based on predefined criteria.

The sortation process is tailored to meet the specific needs of a facility and can sort items by various characteristics such as size, weight, destination or other factors relevant to your warehouse operations.

A sortation system classifies items on a conveyor belt then directs them to different areas in a warehouse based on predefined criteria, such as size, weight, destination or priority.

These systems play a crucial role in different processes, including replenishment, order fulfillment, kitting, cross-docking and returns handling.

Sortation systems can be manual or fully automated.

Manual sortation systems often rely on human intervention, with workers physically sorting or assisting in the sorting process.

On the other hand, automated sortation systems utilize advanced technologies such as sensors, conveyors, barcode scanners and software to automatically identify and route inventory to their designated locations without human intervention.

Key Components of a Sortation System

A sortation system consists of several key components that work together to efficiently sort and route items to their destinations.

• Induction points: This is where inventory enters the sortation system, marking the starting point of the automated sorting process.
• Identification stations: Sortation systems utilize RFID or barcode scanners to identify items and feed information into a control system.
• Conveyor belts: These transport items through the system, connecting all components in the sorting process.
• Diverters: These physically redirect items off the conveyor to destinations such as chutes, containers for consolidated orders ready for outbound shipment, or other conveyors leading to specific areas.
• Sensors: These are used throughout the system to detect item presence, position, size, and other critical data needed for proper sorting
• Control software: This leverages scanned information and programmed logic to determine the correct path for an item within the warehouse.
• Discharge Points/Outfeeds: These are the final destinations where sorted items are delivered, such as bins, chutes, or other conveyors.

Common Sortation System Applications

Multiple industries and sectors take advantage of automated sortation systems to enhance their sorting and distribution processes.

Courier and Logistics

Sortation systems are essential in courier and logistics centers for sorting and directing packages to different locations, such as specific cities, regions or delivery routes.

These systems boost the speed and efficiency of package distribution, decrease errors and refine overall delivery performance.

Retail

Sortation systems play a crucial role in eCommerce and retail distribution centers by managing the high volume of incoming orders.

These systems effectively sort and direct individual items or packages to their intended destinations, ensuring quick and precise order processing.

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Food and Beverage Distribution

Sortation systems in food and beverage distribution centers efficiently manage the flow of products, prioritizing items based on specific needs such as temperature control for dairy or expiration dates for perishables like fruits and vegetables.

These systems further preserve quality, minimize waste and prevent spoilage.

Pharmaceutical and Healthcare

From over-the-counter medications to specialized medical equipment, sortation systems in the pharmaceutical and healthcare sectors manage the distribution of a wide range of products.

They ensure the precise sorting and timely delivery of essential items to hospitals, clinics, pharmacies and patients, supporting the critical infrastructure of healthcare services.

Manufacturing and Production

Sortation systems are essential on production lines for items such as automotive parts and electronics, where they streamline the flow of items through assembly, packaging and shipping stages.

These systems significantly enhance workflow efficiency and boost productivity.

Airport Baggage Handling

Sortation systems automate the routing and sorting of luggage by using advanced scanning and conveyor technologies to read baggage tags and direct each piece to the appropriate flight, gate or carousel.

This precise coordination ensures accurate loading of luggage onto the correct aircraft, increases baggage handling efficiency and lowers the likelihood of misrouted or lost luggage.

Postal Services

Sorting machines are utilized in postal operations to automate the sorting and handling of mail.

They read addresses and categorize letters, envelopes and parcels according to their postal codes or other predetermined criteria.

This allows postal services to process large volumes of mail with greater efficiency.

Key Benefits of Automated Sortation Systems

Automated sortation systems provide valuable benefits for optimizing warehouse operations, including:

• Increased efficiency, accuracy and speed: Automated sortation systems handle high volumes of items quickly, substantially reducing the time goods spend moving from receiving to shipping and significantly outperforming manual sorting methods.
• Enhanced order accuracy: The precision of automated systems reduces the potential for errors, decreasing the incidence of costly returns.
• Better customer satisfaction: Ensuring accurate and timely shipments, these systems revamp service levels and boost customer satisfaction.
• Impact on order fulfillment: The true value of automated sortation systems lies in their ability to optimize the order fulfillment process, directly influencing overall customer satisfaction.
• Lower operational costs: Enhanced efficiency enables more effective use of labor and resources, leading to lower operational expenses.
• Scalability and adaptability: Automated sortation systems can be easily scaled or reconfigured to handle changes in order volume, product types, or fulfillment strategies, making them a flexible solution for growing and evolving warehouse operations.

Faster and more accurate sorting

Handles large item volumes quickly, speeding up warehouse operations.

Less errors

Minimizes errors in order handling, cutting down on costly returns.

Improved customer satisfaction

Ensures timely and accurate deliveries, boosting service levels.

Optimized fulfillment

Streamlines picking and shipping processes for better performance.

Lower costs

Maximizes labor and resource efficiency, lowering overall expenses.

Scalability and adaptability

Easily adapts to changes in product mix, volume, or business growth.

Factors To Consider When Choosing the Right Automated Sortation System

When choosing a sortation system, consider the following factors:

• Throughput needs: The average and peak quantities of items to be sorted per hour or day should align with the system’s capabilities.
• Item features: The size, shape, and weight of the items will determine their compatibility with various sortation methods.
• Adaptability and expansion potential: The system should be flexible to accommodate shifting business requirements and scalable for anticipated growth.
• Integration features: Assess how easily the system can integrate with existing warehouse management system (WMS) and other technologies.
• Budget: Weigh the initial investment costs against the potential for long-term savings and improved efficiency.

Optimize Logistics and Inventory Management With Modula ASRS

Automated sortation systems and Modula automated storage and retrieval systems (ASRS) work together to streamline warehouse efficiency and accuracy.

Here’s how they integrate and function in a logistics setting:

• Storage and retrieval with Modula ASRS: Modula systems automatically store and retrieve items based on software commands. They use vertical lift modules (VLMs) and horizontal carousels to maximize space utilization and improve accessibility. In warehouses, these systems efficiently manage high-density inventory with precision.
• Integration: Once the Modula ASRS retrieves items, automated sortation systems take over to direct them to the appropriate processing, packing, or shipping areas. These systems optimize the movement of goods and reduce manual handling.
• Sorting and routing: Automated sortation systems use barcode scanners, RFID readers and optical recognition technology to identify items and determine their destinations. Conveyors or robotic transport systems then route the items efficiently, optimizing workflow and preventing bottlenecks.
• Seamless coordination: The integration between Modula ASRS and sortation systems enables real-time data exchange and operational synchronization. This ensures items move smoothly from storage to sorting and dispatch, minimizing delays and human errors.
• Software and control systems: Both Modula ASRS and automated sortation systems are integrated with a WMS, which oversees inventory, order processing and fulfillment operations. This seamless integration facilitates real-time data exchange between the sortation system and the WMS, eliminating delays and ensuring accurate tracking and timely updates of item statuses within the inventory system.

In today’s fast-paced world of e-commerce, warehouse automation has become a critical component for businesses striving to meet the growing demands of customers. One essential aspect of warehouse automation is the use of conveyor sortation systems.

What are conveyor sortation systems?

Conveyor sortation systems are advanced technology solutions designed to streamline and optimize order fulfillment processes within a warehouse environment. These systems automate the movement of products, enabling quick and accurate sorting, routing, and distribution.

How do conveyor sortation systems work?

Conveyor sortation systems consist of a network of conveyors that transport items through different stages of the sorting process. As products move along the conveyor, they are identified and sorted according to predefined criteria, such as destination, size, weight, or SKU.

There are several types of conveyors:

• Gravity Conveyor – This type of conveyor uses the power of gravity to move packages along the fulfillment line. They are height-adjustable to create a slight decline along the line to allow packages to flow along rollers or skate wheels. They are ideal for moving lightweight cartons, trays, or totes short distances in a facility.
• Powered Conveyor – These systems function with a mechanical device that moves products and materials along a conveyor line. There are two types of powered conveyors: roller and belt conveyors.
• Motorized Driven Roller Conveyor (MDR) – These conveyors use a chain or belt driven by multiple smaller, low-voltage motors. MDR conveyors are a more efficient and greener solution than high-voltage motor-driven conveyors. They facilitate smooth product accumulation, require minimal maintenance, and achieve high throughput rates.
• Vertical Reciprocating Conveyors (VRCs) – These conveyors are typically utilized in facilities with multiple levels of storage where materials need to flow up or down vertically depending on picking or replenishment activities. They offer material lift efficiencies by providing quick conveyance of products from mezzanines, pick modules, and other multiple-level environments.
• Conveyor Sortation – This type of conveyor system involves identifying products on a line and redirecting the item to a specific location based on a set of criteria. In high-volume distribution centers, automated sortation solutions can be added to conveyors to support quicker and more accurate fulfillment.

When considering diverse perspectives, it is important to keep in mind that not all conveyors may be suitable for all types of products or facilities. Additionally, some conveyors may require more maintenance or have higher energy consumption than others, which could impact the environment. Finally, it is important to ensure that conveyors are designed and implemented with safety in mind to avoid any potential accidents or injuries in the workplace.

Various technologies are employed in conveyor sortation systems. For instance, barcode scanners, RFID tags, and vision systems are used to capture data about each item. This data is then used to determine the appropriate sorting destination for the product.

Once sorted, the items are directed down specific lanes or chutes, leading them to the appropriate dock door or distribution area for further processing. The entire process happens seamlessly, ensuring efficient order fulfillment.

Contact us to discuss your requirements of Sortation Equipment. Our experienced sales team can help you identify the options that best suit your needs.

Benefits of conveyor sortation systems

• Increased throughput: Conveyor sortation systems enable warehouses to handle high volumes of products quickly and efficiently. By automating the sorting process, warehouses can speed up order fulfillment, reducing lead times and improving customer satisfaction.
• Accuracy: Manual sorting processes are often prone to errors. Conveyor sortation systems eliminate these errors by ensuring accurate identification, sorting, and routing of products. This helps minimize order inaccuracies and reduces the risk of shipping errors.
• Flexibility: Conveyor sortation systems offer modular designs that can be easily customized to suit the specific needs of a warehouse. Whether it’s handling different product sizes, weights, or packaging types, the system can be tailored to meet the unique requirements of the operation.
• Space optimization: By utilizing vertical space and compact designs, conveyor sortation systems help warehouses make the most efficient use of their available space. This is especially beneficial in urban areas where warehouse real estate is limited.
• Improved labor productivity: With automated sorting systems, warehouse staff can focus on more value-added tasks instead of manual sorting. This leads to increased labor productivity and allows employees to work on more complex operations.
• Real-time tracking and traceability: Conveyor sortation systems integrate with warehouse management systems, providing real-time visibility into the status and location of each product. This enhances inventory control and allows for better tracking and traceability, reducing the risk of lost items.