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.
