The Sortation Palooza

Track T5 Session #1
 Marc Wulfraat Bob Kregel
▪ President ▪ V.P. Global Product Management

▪ MWPVL International ▪ Dematic

▪ [email protected] ▪ [email protected]

▪ 514-482-3572 x 100 ▪ (262) 860-6503

▪ www.mwpvl.com ▪ www.dematic.us

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Abstract
Sortation systems have been acknowledged as "the heart of the
modern distribution center."

Fueled by the impatience of ecommerce customers, the eruption of

SKUs and the intertwined network resulting from omnichannel,
sorting goods inside the DC has gone from complex to perplexing.
In this comprehensive review, our sortation scholars will present a
multitude of contemporary sortation solutions in terms of function,
specifications and application. A deliverable from this class will be
a clear selection matrix to aid you in making design decisions that
you won't regret.

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Agenda

 What is a sortation system and when is it needed?

 What are the basic components of a sortation system?
 What types of sortation systems are available?
 What options exist?
 What considerations are important when choosing a
sortation system?
 Questions & Discussion

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Sortation Definition
Sortation is a process that orders items according to
specified criteria

It can serve as the heart

of an efficient
distribution center
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Sortation System Definition

 Sortation can be a manual process, a semi-automated

process, or a fully-automated process
 A sortation system identifies products and/or
packages (i.e. entities) and in turn transports, merges,
inducts, separates, sorts, routes and/or consolidates
these entities to specified destinations as per the
requirements of the distribution operation

Sortation

6
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When Do We Need Sortation Systems?
 Sortation systems are typically deployed when
a distribution center has one or more of the
following characteristics:
- Batch picking: Multiple orders are grouped together and picked as a
single parent order to reduce travel time and afterwards the child
orders need to be sorted
- Multiple pick areas and/or material handling technologies are
picked independently and in parallel; and need to be merged prior
to packing
- Goods need to be moved between different areas, floors and
buildings
- Completed orders need to be sequenced prior to loading (e.g. by
carrier, by weight, by load/stop)
- Flow through distribution such as in the Retail Industry

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The Main Benefits of Sortation

 Sortation systems allow companies to increase

throughput in a distribution center because
picking processes can be in parallel instead of
in serial
 The enabler for high speed batch picking and
flow through operations which remove
significant labor cost from a DC operation
 Highest levels of shipment accuracy can be
achieved

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Sortation System Design Considerations
Decision Criteria Design Data Requirements
Throughput Volume Requirements • Average and peak of sorts per minute
& Speed • Average and peak diverts per minute through
each destination point
Packaging format, size, shape, • Type of packaging material, fragility, weight
diversity, and conveyability of distribution, flatness of entity
packages • Product orientation
• Product mix
Unit Load Characteristics • Length, width, height, weight of entity being
sorted
Operating Environment • Temperature, dust, oil, obstructions
Physical Site Constraints • Columns, clear height, doors
Accumulation & Recirculation • Buffer requirement leading up to sortation
Requirements • Recirculation after sortation discharge
Financial • System cost and ROI
Other Considerations • Ergonomics, noise, energy requirement,
maintenance, equipment interfaces
• Bar code label size, location & symbology
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Different Types of Sortation Systems
Sortation Type Available Technologies

Manual  Put Wall / With Lights

Conveyor Systems  Right angle transfer with bands or rollers

 Conveyor with swing arm, pusher or deflector
 Strip-Belt Sorter
 Positive Belt Sorter
 Swivel wheel sorter or pop-up wheel sorter
Linear Sortation  Sliding Shoe with Angle Divert
 Sliding Shoe with Parallel Divert
 Sliding Shoe with Bi-Directional Divert
Circulation Sortation  Cross-belt sorter
 Tilt tray sorter
 Bomb-bay sorter (1-tray, 2-tray, quad-tray)
Automation  Shuttle system

Please note that there are other types of specialty and hybrid sortation systems not listed here that are excluded
due to time limitations for this presentation.

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Sortation System Component Diagram

Merge Induction Sorter Take-Away Controls

Facilitates Minimizes gaps Diverts items Moves items Tracks items
Flow of Unit between loads and to one or two away from and ensures
Loads maximizes the flow sides the sorter accurate
onto the sorter flow

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Sortation System Components in Detail
Subsystem Options Description
Merge • Merge Options • Receives products/cartons from
- Single various sources or areas
- Dual • Controls / regulates / funnels /
- Sawtooth singulates the flow of cartons into a
- Multilane single stream prior to sortation
Induction • Gap Options • Gateway to sortation system
- Brake belt or meter belt • Identifies carton and destination
- Blow through • Gaps and spaces cartons to
- High rate gapping unit optimize sortation system
Sortation • Tracking Options • Tracks carton through to
- Relays, Programmable logic downstream destination
controllers (PLC), Computers • Activates diverter device
- Diverter Options • Sorts cartons/packages into
- Manual, plow, pusher, pop- different streams
up, slat-shoe, tilt- tray, etc.
Takeaway • Takeaway Options • Transport / takeaway cartons away
- Conveyors from sorter
- Chutes, Spirals • Feed downstream pack stations or
- Drops shipping stations

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 Review of Different Types
of Sortation Systems

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Manual - Put Wall Sortation / With Lights
 Operator scans incoming tote
license plate
 Put to Light identifies the cubby
hole to sort product/quantity to
(30 – 75 cubby holes typically)
 Confirm by pushing button on
light panel
 Product removed from other
side of wall for packing

Typical Applications Pros / Cons / Considerations

↑ Provides integrated order consolidation
Upstream batch piece picking process
and packing
Upstream goods to person automation ↑ System-directed manual process
↑ Flexible, scalable, mobile (wheels), low
Upstream pre-put picking process
cost alternate to mechanized sortation
Small orders with few order lines (e.g. e-
↓ Limited throughput volume rate
commerce, catalogue, customer-direct)

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Put Wall Video

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Conveyor with Right Angle Transfer
 Powered roller conveyor with 90° bi-directional package
transfer to left or right
 Pneumatic lift used to divert package

 Standard diverter with pop-up straps has a lower

sortation rate of 25 - 30 cartons sorted per minute
 High Speed diverter with pop-up rollers can sort up to 25
- 60 cartons per minute
 Requires a flat-bottom entity such as a carton or tote

Typical Applications
Standard diverter handles minimum carton dimensions
of 6”W x 9”L with 2 – 110 LBs at 180 feet/min
High speed diverter handles minimum carton dimensions
of 9”W x 9”L with 2 – 110 LBs at 240 feet/min
Merge batch picked items to a highway lane
Divert / sort items/cartons to picking zones
Medium throughput sortation to shipping lanes

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Conveyor With Right Angle Transfer

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Conveyor with Swing Arm or Paddle or Push
Deflector
 Powered roller conveyor with 45°-90°
package transfer to left or right
 Pneumatic swing arm, pusher arm or
deflector arm used to divert package
 Right angle Pusher can sort 25 – 50
cases/totes per minute
 Swing arm diverters can sort 25 - 60
cases/totes / minute
 Some applications can go higher

Typical Applications Pros / Cons / Considerations

Divert / Sort cartons or totes to conveyor ↑ Medium cost, flexible and modular
lanes for transfer to new pick zones or to diverter that can easily be relocated
shipping lanes within a conveyor system
Standard pusher handles minimum carton ↓ Higher speed pusher diverters can have
dimensions of 4”W x 6”L x 2”H with 2 – 75 a high impact on the product being
LBs at 250 feet/min sorted

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Swing Arm, Paddle & Push Deflectors

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Conveyor Strip-Belt Sorter
 Bi-directional right angle
transfers
 Motorized pulley drive with
pneumatic transfer lift elevates
high strength belts
 Designed to sort parcels up to
100 Lbs at speeds of 25 - 65
items/cartons/totes per minute
 Often used to sort loose units or
totes

Typical Applications Pros / Cons / Considerations

Suitable for totes, trays and for rigid form ↑ Highly energy efficient
factor products like CDs, DVDs, returns ↑ High strength belt
sortation ↓ Product weight constraint

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Conveyor Strip-Belt Sorter

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Conveyor Positive Belt Sorter
 Pneumatic lift mechanism causes
cartons to divert to left or right on a
30° angle
 Powered belts face package flow for
diverting
 One or two belts used depending on
width of conveyor to reduce minimum
gap requirements and maximize rate
 25 - 60 cartons/totes sorted per
minute

Typical Applications Pros / Cons / Considerations

Generally applied to low throughput ↑ Energy efficient
applications
Divert / Sort cartons/totes to destination lanes ↓ Limited throughput volume rate

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Conveyor with Steerable Wheel Pop-Up
Roller Wheel diverter
 Pneumatic rotary actuator turns wheels
for diverting cartons 30° to left or right
 Wheels rotate or pop up to divert
package
 Steerable wheel diverter can sort 30 - 80
items per minute
 Pop-up wheel diverter can sort 35 - 100
items per minute

Typical Applications Pros / Cons / Considerations

Steerable wheel handles min. carton ↑ Flexible and modular diverter that can
dimensions of 3”W x 9”L up to 24”w x 36”L easily be relocated within a conveyor
with 2 – 110 LBs at 315 feet/min system
Pop-up wheel handles minimum carton ↑ Range of throughput rates supported
dimensions of 6”W x 9”L up to 26”w x 36”L
with 4 – 100 LBs at 350 feet/min
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Steerable Wheel Sorter

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Linear Sliding Shoe Sorter Angle Divert
 High-Rate Sorter

 Aluminum slats (typ. 4”) with

sliding shoes
 One sided, 30° sorting

 100 – 280 cartons per minute

throughput capacity
 Speed of up to 150 to 600+ ft/min

Typical Applications Pros / Cons / Considerations

Angled divert handles minimum carton ↑ Possibility to eliminate chain drive, no
dimensions of 4”W x 6”L up to 41”w x lubrication
48”L with 2 – 100 LBs at 540 feet/min ↑ Electro-mechanical divert switch (no air)
↑ Automatic speed control for throughput
fluctuations saves energy & reduces wear
Applied for high throughput applications ↓ Higher cost system

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Linear Sliding Shoe Sorter Parallel Divert
 Ultra High-Rate Sorter

 Aluminum slats (typ. 4”) with

sliding shoes
 One sided, 30° sorting

 150 – 380 cartons per minute

throughput capacity
 Speed range 150 – 600+
feet/min.
Typical Applications Pros / Cons / Considerations
Parallel diverting provides the highest sortation ↑ Possibility to eliminate chain drive, no
rate & slowest transfer speed lubrication
↑ Automatic speed control for throughput
Parallel divert handles minimum carton fluctuations saves energy & reduces
dimensions of 4”W x 6”L up to 34”w x 60”L wear
with 2 – 154 LBs at 590 feet/min ↑ Smaller gap required between cartons
High throughput retail sortation applications ↓ Higher cost system

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Linear Sliding Shoe Bi-Directional Divert
 Mid-Rate Sorter that requires low space

 Aluminum slats (typ. 4”) with sliding

shoes
 Two-sided, 30° angled sorting

 100 - 280 cartons per minute throughput

capacity
 Speed range 150 – 540 feet per minute

Typical Applications Pros / Cons / Considerations

Applied for medium/high throughput ↑ Possibility to eliminate chain drive, no
applications as an alternative to pop up lubrication
wheel sorters ↑ Electro-mechanical divert switch (no air)
↑ Automatic speed control for throughput
fluctuations saves energy & reduces wear
Bi-directional divert handles minimum ↓ Higher cost system
carton dimensions of 3”W x 6”L up to 31”w
x 48”L with 0.2 – 110 LBs at 320 feet/min
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Sliding Shoe Sorter

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Circular Sortation – Cross Belt Sorter
 High-speed bi-directional sorter
diverts items or cartons 90° left or
right
 Divert points can be at close
intervals for space efficiency
 Performs True Positive Active
sortation
 Single, twin, double deck and quad
cell
Typical Applications Pros / Cons / Considerations
High speed throughput applications that can ↑ Flexible and modular diverter that can
handles minimum item dimensions of 3”W x easily be relocated within a conveyor
3”L x 0.1”H up to 24”w x 47”L with 0.2 – 110 system
LBs at 360 - 490 feet/min
Diverts units or cartons to destination lanes ↑ Flexibility to sort a wide range of entities
of their shape, size and surface
characteristics

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Circular Sortation – Cross Belt Sorter

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Circular Sortation – Tilt-Tray
 High-speed chain-driven 2-way sorter
used for a wide mix of unit or parcel
sortation
 Wide choice of induction units and chute
designs
 Flexibility to scale down throughput
speed to reduce product impact
 Speed can range 400 – 500+ ft/min

 Can sort 23,000 - 25,000+ pieces per hour

depending on design
Typical Applications Pros / Cons / Considerations
Applied where a diverse range of units or ↑ High-accuracy, high-speed, low-noise
parcels are sorted to destination chutes/lanes. system that is scalable
↑ Modular by design – flexible to change
Commonly used to sort a wide range of ↑ Handles a diverse range of items and
products including apparel, small items in poly parcels
bags, mail envelopes, courier parcels, DVD’s, ↓ Can requires a larger footprint
CD’s and small to large corrugated boxes. depending on the design

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Circular Sortation – Tilt-Tray

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Circular Sortation – Bomb-Bay
 High-speed continuous loop sorter that is
typically an oval race track traveling at ~140 feet
per minute
 8 operators can manually induct up to 40,000
pieces/hr at 2 ends of the loop
 Also known as a split tray or quad tray sorter
because trays can be divided into 2 or 4 sub-
trays

Typical Applications Pros / Cons / Considerations

Often used to sort apparel / soft ↑ High-accuracy, high-speed sortation that can
goods, or small products that can fit scale to low throughput applications
on a tray and that are not fragile. ↑ Less space requirement because chutes can be
directly below the sorter
↓ Efficiency constraints when 4 people induct at
one induction station
↓ Each wave release requires time to reset the
shipping cartons under the sorter

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Circular Sortation – Bomb-Bay

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Automation – Shuttle System
 Shuttle robots can be used as an alternative
to traditional sortation systems
 Shuttles can stage totes or cartons selected
from one or many pick zones in the DC
 Totes are staged and then released for
outbound deliveries in optimal sequence
 Heaviest totes can always be on bottom of
pallet for ergonomic considerations

Typical Applications Pros / Cons / Considerations

Retail– merge and consolidate totes ↑ High-accuracy sortation that can scale to high
from conventional pick areas and throughput applications
release by store in aisle/weight ↑ High storage density / low footprint
sequence ↑ High-flexibility solution

E-commerce home delivery for food ↓ Higher thoughput requires more shuttles
– sort by route and stop therefore more cost

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Application Selection Guidelines

(8,000 to 40,000+)

(6,000 to 18,000)

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 Sorter Selection Guide (Throughput)
Sorter Selection Guide Based on Sortation Rates of a Standard 16" Carton
Throughput Rate Low Rate Mid Rate High Rate
Right Angle Right Angle Pusher Strip Positive Swivel Pop-Up Sliding Shoe Sliding Sliding Shoe Tilt Tray Cross Belt Bomb Bay
(Cartons/ (Cartons/
Transfer Transfer Diverter Belt Belt Wheel Wheel Bi-Directional Shoe Angle Parallel Sorter Sorter Sorter
Hour) Min)
(Bands) (Rollers) Sorter Sorter Divert Divert Divert Divert Divert
25,000 - 40,000 420 - 670

18,000 - 25,000 300 - 420

15,000 - 18,000 250 - 300

12,000 - 15,000 200 - 250

10,200 - 12,000 170 - 200

8,400 - 10,200 140 - 170

6,600 - 8,400 110 - 140

4,800 - 6,600 80 - 110

3,600 - 4,800 60 - 80

2,700 - 3,600 45 - 60

2,100 - 2,700 35 - 45

1,500 - 2,100 25 - 35

900 - 1,500 15 - 25

0 - 900 0 - 15

Legend: Low Fit Med. Fit Optimal Fit Optimal Fit

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 Summary of Sortation Systems
Sortation Throughput Technology Typical Max Metric System Cost Flat Bottom Takeaway Options
System Rate per Hour Rate Rate Required
Manual Put Up to 700 Pick/Put to Light 7 12 Items per min. Low No Pack Station or
Wall Items/hour Powered conveyor
Right angle transfer diverter 25 30 Cartons/Totes per Low Yes Powered conveyor
with straps min.
Right angle transfer diverter 25 60 Cartons/Totes per Low Yes Powered conveyor
with rollers min.
Flat belt conveyor with swing 25 60 Items/Cartons/Totes Low No All
arm, pusher arm, or deflector per min.
Conveyor Up to 7500 diverters
Diverter cartons or totes Strip-Belt Sorter Diverter 25 65 Items/Cartons/Totes Medium No All
Systems per Hour per min.
Positive Belt Diverter 25 65 Cartons/Totes per Medium Yes All
min.
Swivel/steerable wheel diverter 30 80 Cartons/Totes per Medium Yes All
min.
Pop-up wheel diverter 35 100 Cartons/Totes per Medium Yes All
min.
Bi-Directional Divert 100 280 Items/Crt per min High No All
Linear Sliding 9,000 to 24,000
Angle Divert 100 280 Items/Hour High No All
Shoe Items/hour
Parallel Divert 150 380 Items/Hour High No All
Circulation Cross-belt sorter 350 500 Feet/Minute High No Chute
Sortation 8,000 to 40,000+ Tilt tray 350 500 Feet/Minute High No Chute
Items/hour Bomb-bay (1-tray, 2-tray, quad- 120 140 Feet/Minute High No Drop, Chute
tray)
Automation Shuttle System Customized High No Powered Conveyor

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Key Takeaways
 Many sortation systems are available on the market and
we have only discussed the more common ones
 Sortation system costs generally increase as
throughput rates increase
 It is key to identify throughput rate requirements,
packaging format, weights, shapes, sizes of products,
cartons or totes to be sorted
 There is an optimal sorter for each type of application
and the guidelines presented here provide a basic
starting point towards this objective

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Conference Cloud Additional Resources
 Put Wall
- http://www.youtube.com/watch?feature=player_detailpage&v=NToQfX3NseQ

 Linear Sorters
- http://www.youtube.com/watch?v=2TJ4NYHuXPI&feature=player_detailpage

 Conveyor Sorters
- https://www.youtube.com/watch?v=PvLoU9D07s0
- http://www.youtube.com/watch?v=F-ZdQGtaItU&feature=player_detailpage
- http://www.youtube.com/watch?v=pSemAc9s7XQ&feature=player_detailpage

 Cross Belt Sorters

- http://www.youtube.com/watch?v=HGkpXNQzZuQ&feature=player_detailpage

 Tilt Tray Sorters

- http://www.youtube.com/watch?feature=player_detailpage&v=PM7dRuFmHI4
- http://www.youtube.com/watch?v=_RrU_AAqPtE&feature=player_detailpage

 Steerable Wheel Sorters

- https://www.youtube.com/watch?v=PvLoU9D07s0

| 2014 M AT E R I A L H A N D L I N G & L O G I S T I C S C O N F E R E N C E S P O N S O R E D B Y D E M AT I C | W W W. M H L C . C O M | 40
 Questions

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| 2014 M AT E R I A L H A N D L I N G & L O G I S T I C S C O N F E R E N C E S P O N S O R E D B Y D E M AT I C | W W W. M H L C . C O M |