The importance of selecting the right sorter system is growing every day. Order fulfillment centers, warehouses, and courier distribution centers are challenging operation zones where various types of cargo and packages are processed, sorted, loaded onto vehicles, and distributed. These operations, which are essentially races against time, are highly prone to errors and losses.

Businesses that strive for balancing profitability and efficiency can achieve high gains and flawless systems through well-planned structures and the right sorter selection. So, how do you choose the right sorter? Which sorter system is the most suitable and useful for your warehouse? Several factors determine the answers to these questions. These factors are directly related to needs, the structure of the operation, and future plans.

Factors Influencing Sorter System Selection

1-Number of Packages Processed Per Day and Hour

One of the most important factors to consider when designing a sorter system is the volume of orders or product. To determine this, you should look at the number of packages processed per day.

While sorter devices with basic components are typically sufficient for smaller-scale operations, larger warehouses and courier centers may have additional requirements. Sorter systems used by companies processing 1,000 packages daily will significantly differ from those processing 10,000-20,000 packages.

For example, a company handling fewer orders might need a roller-belt or wheel sorter system, while one handling over 10,000 items will inevitably require a cross-belt or shoe sorter. Moreover, choosing a system beyond your needs can be disadvantageous in terms of initial setup costs since high-quality sorter systems come with considerable expenses. Therefore, wrong choices can negatively affect efficiency.

The daily transaction numbers of courier distribution centers, warehouses, and order fulfillment companies are generally predictable. However, periods of global or local peaks in demand are highly likely. During high-demand periods, such as Black Friday or Cyber Monday, the number of packages processed in a day can differ significantly from other periods.

During these times, the sorter systems' workload will peak similarly. However, poorly chosen and improperly installed sorters may fall short of meeting this intense demand. In such cases, the solution is to consult the sorter manufacturer to address deficiencies and build a sorter system that won’t disrupt warehouse operations.

Another important aspect is the bottleneck hours such as having only certain number of hours to process certain packages. Sorter operators should select their sorter type considering daily package count, peak time of the year and also bottleneck hours.

Problems in Dimensioning

In operations such as order fulfillment or stock management, different products need to be processed quickly and accurately. These products may have regular or irregular shapes, different weights or packaging like shiny or black foils. This leads to an increase in inaccurate measurements and errors, and a decrease in profitability and efficiency. It also negatively affects customer satisfaction levels and damages the brand's reputation.

Another problem faced in warehouses and distribution centers is the danger of lost products. Packages can get lost in the processing process and become a problem. This kind of problem causes problems on the customer side and disrupts the process.

Efficiency is also an issue of serious importance for businesses. In order to ensure the continuity and sustainability of a brand, it must meet efficiency criteria. Factors such as operating costs, number of employees, profitability and the amount of product processing per hour play a decisive role in evaluating productivity. Businesses that operate with low productivity experience great difficulties until this problem is understood. In summary, manual processes where productivity cannot be measured means being unaware of all these problems.

New Generation Static Parcel Dimensioning Systems

2-Size and Weight of Processed Packages

In the logistics sector, which encompasses commerce and e-commerce activities, all products are subject to transportation and delivery services. This means that hundreds of different-sized packages and boxes are involved in the order fulfillment process. Although larger, more complex sorter systems can handle bigger operations, size is not the only determining factor.

The weight of the products plays a crucial role in sorter type selection as well; the features of the packages dictate the sorter technology and their characteristics. For example, in a sorting operation involving fragile and sensitive products, using a sliding shoe sorter system can significantly prevent potential damages.

3-Grow Expectations Over Three Years

Every logistics organization's scale and structure are different, and growth strategy is one of these differences. For companies that have been operating for years with stable systems, the growth rate is typically slower. For these companies, determining the necessary sorter system is relatively easy and accurate. However, for smaller, newer brands, warehouse operations may experience larger fluctuations, and the growth rate may be higher.

For this reason, growth rate is an important factor that logistics providers should consider when building a sorter system. These systems are expensive to set up initially, and potential updates can disrupt daily operations. In some cases, adding only chute modules may be sufficient, while in other cases, a second or third sorter system may be needed. In summary, having a roadmap before investing in sorter systems is beneficial.

4-Available Space for Sorter Installation

Sorter systems are logistics elements that occupy permanent physical space due to their structure. These systems can cover large areas depending on factors such as the number of chutes, sorter type, and the scale of the order fulfillment company.

It’s essential to ensure there is enough space in the warehouses for the sorter to function properly and increase operational efficiency, and support should be sought from the sorter manufacturer. Proper layout is critical for a sorter system to operate quickly and accurately.

3-Is DWS Required?

While sorter systems consist of basic components, they can be equipped with additional capabilities to create a much more versatile structure. Sorters with equipment like volume measuring devices, weight scales, and barcode readers allow the entire operation to be managed more quickly and in a more controlled manner. These sorter systems manage and track the entire process from the moment the product arrives at the warehouse or distribution center until it is loaded onto a truck, ensuring smooth operations.

Additionally, warehouse management software can collect and process the data gathered by each component, eliminating manual order fulfillment errors, package or product losses, and reduced efficiency, thus enabling top-level operations. The ultimate goal of this entire process is the creation of a technological warehouse automation system built with sorter systems equipped with all these features. Although the initial setup of automation systems can be costly and time-consuming, the long-term advantages they provide are immensely beneficial, making it a highly lucrative investment.

To review our products and get detailed information about sorter systems, dimensioners or warehouse automation management software; you can check our product page and you can send an e-mail to info@beevision.ai to reach us.