Advanced Sortation Systems for Distribution
We deliver turnkey sortation systems for high-speed order fulfillment across Connecticut and the Northeast & Mid-Atlantic. Our expertise includes complete integration with advanced automation technology, including crossbelt sorters, sliding shoe sorters, pop-up wheel diverters, bomb bay sorters, tilt tray systems, and narrow belt sorters. Every installation integrates with conveyor systems and merge systems for optimal throughput.
Types of Sortation Systems
Crossbelt Sorters
High-speed linear sortation with individual cross-belt carriers traveling on main conveyor belt. Bi-directional discharge capability handles wide variety of products and package sizes up to 75 lbs. Ideal for e-commerce fulfillment and parcel sortation.
Sliding Shoe Sorters
Precision high-speed sorting with individually controlled sliding shoes that gently divert products at 15 to 45 degree angles. Excellent for packages, poly bags, and fragile items requiring gentle handling. Sorting rates exceed 15,000 items per hour.
Pop-Up Wheel Diverters
Reliable mechanical systems for 90-degree product diversion. Belt-driven wheel technology provides low maintenance operation for boxes, totes, and cartons. Cost-effective solution for right-angle transfers in distribution applications.
Bomb Bay Sorters
Drop-through sortation with retractable belt sections for gravity discharge. Perfect for heavy items, irregular packages, and high-volume applications. Products discharge to lower conveyors, chutes, or containers when belt sections retract.
Tilt Tray Sorters
Individual tilting trays mounted on continuous loop conveyor provide precise product discharge at designated locations. Variable tilt angles accommodate small items, bottles, cosmetics, and delicate products. Excellent for retail distribution and e-commerce.
Narrow Belt Sorters
Compact narrow belt diverter systems for space-constrained applications. Multiple parallel narrow belts independently controlled for precise product diversion. Ideal for polybags, small parcels, and mixed product streams in fulfillment centers.
High-Speed Parcel and Carton Sortation
Modern distribution centers require sortation systems capable of processing thousands of items per hour with near-perfect accuracy. Our high-speed sortation solutions integrate barcode scanning, dimensioning, weighing, and label application into continuous automated flow.
Parcel sortation capabilities include:
- Throughput Rates: Systems designed for 5,000 to 15,000+ items per hour depending on configuration
- Package Range: Handle products from small parcels 4"×6" up to cartons 30"×30"×30"
- Weight Capacity: Products from 0.1 lbs to 75 lbs per system type
- Sort Accuracy: 99.5%+ sort accuracy with proper barcode quality and system setup
- Destination Count: Support for 50 to 500+ sortation destinations in single system
- Induction Methods: Manual induction, automatic singulation, or high-speed induction conveyors
WMS and WCS Integration
Sortation systems require sophisticated warehouse management system integration and warehouse control system software to manage product flow, destination routing, and real-time decision making. Our control packages provide seamless connectivity with existing warehouse management systems.
Control System Features
- Real-Time Communication: WMS interfaces using OPC, TCP/IP, or API protocols for instant data exchange
- Product Tracking: RFID, barcode scanning, and photo-eye tracking from induction through discharge
- Dynamic Routing: Automatic destination assignment based on order priority, carrier, and zone
- Performance Monitoring: Live dashboards showing throughput, sort accuracy, and system status
- Divert Logic: Programmable rules for product routing based on size, weight, destination, or priority
- Remote Diagnostics: Cloud-connected systems enable remote troubleshooting and support
Induction Systems and Recirculation Loops
Efficient sortation begins with proper product induction. Induction systems regulate product flow onto sortation conveyors at precise spacing and timing for optimal system performance. Recirculation loops enable products to make multiple passes when destinations are full or offline.
Induction System Types
- Manual Induction: Operators place products onto takeaway conveyor at controlled spacing
- Automatic Singulation: High-speed singulation conveyors separate products from bulk flow
- Gap Control: Photo-eye systems maintain precise product spacing for downstream sortation
- Speed Matching: Variable speed induction matches product velocity to sorter requirements
- Multi-Lane Induction: Parallel induction lanes merge into single sortation stream
Recirculation Loop Benefits
- Continuous Flow: Products recirculate when destination chutes are temporarily full
- Overflow Protection: Prevents system jams by routing excess products back to sorter
- Priority Sorting: High-priority items can recirculate until destination becomes available
- System Flexibility: Destinations can be taken offline for maintenance without stopping system
- Efficiency Gains: Maintains maximum throughput even during peak demand periods
Key Applications & Industries
- E-commerce Fulfillment: Order sortation by shipping zone, carrier, store allocation, or customer priority
- Postal & Shipping: ZIP code sorting, package classification by service level, destination routing to load areas
- Distribution Centers: Store allocation sorting, cross-dock operations, shipping lane sortation for multi-customer facilities
- Manufacturing: Work-in-process routing between departments, finished goods sortation, packaging line feeding
- Food & Beverage: Product sorting by SKU, case routing to shipping lanes, cold storage distribution sortation
- Pharmaceutical: Order picking support, prescription fulfillment sortation, batch tracking and routing
- Retail Distribution: Store-specific sortation, department routing, seasonal product handling
- Parcel Handling: Third-party logistics sortation, last-mile delivery routing, hub sortation facilities
System Performance & Capabilities
- High Throughput: Sliding shoe and crossbelt systems achieve 12,000 to 15,000+ sorts per hour
- Sort Accuracy: Properly maintained systems deliver 99.5%+ accuracy with quality barcodes
- Package Range: Handle small parcels 4"×6" up to large boxes 30"×30", weights 0.1 to 75 lbs
- Destination Count: Single systems support 50 to 500+ individual sortation destinations
- Integration Ready: Standard interfaces for WMS, WCS, barcode scanners, dimensioners, scales
- Energy Efficient: Variable frequency drives, zone control logic, sleep modes reduce power consumption
- Scalability: Modular design enables system expansion by adding sorter sections and destinations
Sliding Shoe Sorter Technology
Sliding shoe sorters represent the most precise and gentle sortation technology available for high-speed distribution operations. Individual shoes slide across slats at controlled angles to divert products without impact or rotation, making them ideal for poly bags, hanging garments, and fragile items.
Technical specifications:
- Discharge Angles: Available in 15, 22, 30, and 45-degree configurations for various chute designs
- Bi-Directional: Sort products to both left and right sides of conveyor from single sorter
- Modular Design: Add sorter modules and destinations as volume grows without replacing system
- Low Noise: Quiet operation under 75 dBA suitable for warehouse and fulfillment environments
- Maintenance Access: Sliding shoes and drive components accessible from walkway for quick service
- Lubrication Systems: Automatic lubrication reduces wear and extends component service life
Merge System Technology
Merge conveyors seamlessly combine multiple product streams into consolidated flow for downstream sortation or processing. Essential for facilities with multiple pick zones, packing stations, or product sources feeding common sortation system.
Merge system types:
- Zipper Merge: Alternating product placement from two parallel lanes creates single stream
- Priority Merge: Main production line maintains priority with secondary lines filling gaps
- Demand Merge: Merge timing controlled by downstream demand sensors and gap detection
- Speed Matching: Input conveyors automatically adjust speed for smooth product integration
- Dynamic Merging: Control systems analyze product flow and optimize merge patterns in real-time
System Integration & Automation
Complete sortation solutions require integration of multiple technologies working together as unified system. We provide turnkey integration of sortation equipment with peripheral systems for maximum efficiency and reliability.
Integrated Technologies
- Barcode Scanning: Tunnel scanners, overhead scanners, or omnidirectional arrays for 99.9%+ read rates
- Dimensioning Systems: Laser or camera-based dimensioners capture product dimensions for routing and billing
- In-Motion Weighing: Conveyor scales verify package weights without stopping product flow
- Label Printing: Print-and-apply systems add shipping labels immediately before sortation
- Induction Controls: Gap control and spacing systems regulate product flow onto sorter
- Chute Systems: Gravity chutes, powered takeaway, or bag drop systems at each destination
- Controls Integration: Single HMI interface controls entire sortation system and peripherals
Why Choose EHS for Sortation Systems?
With over 30 years of material handling experience in the Northeast & Mid-Atlantic, we understand that sortation systems are mission-critical for distribution operations. Our team provides comprehensive analysis, system design, installation, and ongoing support to ensure optimal performance and reliability. We serve Connecticut, Massachusetts, Rhode Island, New York, New Jersey, and Pennsylvania with local installation crews and 24/7 service support.
Our comprehensive approach includes:
- Detailed throughput analysis and system sizing based on current and projected volumes
- CAD layout and simulation modeling to validate design before purchase
- Complete electrical design, PLC programming, and network integration
- Professional installation by experienced material handling technicians
- System commissioning, testing, and performance validation
- Operator training and comprehensive documentation packages
- Preventive maintenance programs and 24/7 emergency service throughout region
Frequently Paired Solutions
High-speed sortation requires integrated upstream and downstream equipment to maximize throughput:
Roller conveyors provide efficient, low-friction transport for cartons and totes.
Accumulation zones buffer products between conveyor segments to maintain steady flow.
Packaging lines require integrated conveyor delivery systems for continuous product flow.
In-motion scales weigh products without interrupting conveyor throughput.
Pick modules create organized picking zones with integrated storage and conveyance.
Warehouse racking maximizes vertical storage density and organization.
Industries We Serve
High-speed fulfillment infrastructure for online retail operations.
High-throughput sortation and shipping systems for parcel carriers.
Efficient storage and material handling for distribution centers.