Sorting systems have become increasingly essential in warehouses and distribution centers. As the industry expands and the demands for efficient material handling systems grow, companies have invested in automated sorting technologies. With the right sorting systems, warehouses can enhance their productivity, improve accuracy, and reduce labor costs.
What are Sorting Systems?
Sorting systems are material handling systems that enable warehouses to sort a vast amount of items quickly and accurately. These systems use various technologies such as conveyor belts, sensors, barcode scanners, and cameras. The products pass through the sorting system and from there automatically sort to their designated location (storage or outbound). Warehouses can choose from several sorting systems based on their needs, like pop-up sorters, tilt tray sorters, or cross-belt sorters.
One of the most popular and widely used sorting systems is tilt-tray sorters. They can sort a high volume of items based on criteria like packaging, destination, or order number. These systems have been optimized to work with different products, including small items like books or lightweight products like apparel. By incorporating tilt-tray sorters, warehouses improve their operation’s throughput capacity and increase their order accuracy rate.
Advantages of Sorting Systems
Sorting systems bring numerous benefits to warehouses’ productivity, efficiency, and cost. They automate the process of sorting, which reduces the need for manual interventions. As a result, this improves the operation’s accuracy, which reduces the risk of errors in the shipment. This benefits both the warehouse and customers since it leads to faster order processing time and improves delivery times. With more packages being shipped, Sorting systems help reduce labor costs, save time, and increase the warehouse’s efficiency.
Additionally, Sorting systems can sort items to specific locations required for further processing, storage areas, or directly to the outbound spot, which further enhances overall accuracy and reduces handling costs. Another advantage of sorting systems is that, as most of the process is automated, it is easy for warehouses to scale up their operations while maintaining a fixed workforce.
How to Choose the Right Sorting System for Your Warehouse?
Choosing the right sorting system for your warehouse requires consideration of various factors such as warehouse size, product volume, packaging system, weight of the products, and processing speed needed. Based on this information, warehouses should analyze the available sorting systems and select the one that best suits them. Some of the critical factors to consider while choosing are volume capacity, handling time, and system flexibility.
For example, if the warehouse requires a high-sorting rate based on strict size or weight criteria, the cross-belt sorting system may be a better pick. Pop-up sorters can be used for higher volume items with unique or larger dimensions. Tilt-tray sorters, on the other hand, are an excellent choice for a wide array of products. Warehouses can also choose hybrid systems that combine multiple sorting technologies to cater to different product types and conditions.
Implementing Sorting System in the Warehouse
Implementing a sorting system in the warehouse is a massive undertaking that requires careful consideration and planning. The first step towards implementing a sorting system involves assessing the overall configuration of the warehouse and the current material handling system in place. Based on these, warehouses should analyze their sorting system needs and select a suitable one.
Next, it is essential to integrate the sorting system with other warehouse technologies and perform the required maintenance. Once the system is in place, the warehouse must train employees on its proper usage, oversee the process, ensure quality control, and perform the necessary upgrades as needed.
Sorting systems are game-changers for warehouses. They are reliable, efficient, and cost-effective solutions that address the inherently complex nature of large-scale material handling operations. By using sorting systems, warehouses can easily handle high volumes of items, lower labor costs, and boost order accuracy. Choosing the right sorting system based on factors like volume capacity, handling time, and flexibility can lead to greater returns on investment. Implementing a sorting system in the warehouse requires proper planning, training, and maintenance but brings in numerous benefits that can ultimately give a competitive edge to the warehouse’s operational capabilities.