3D Put-Wall E-commerce Fulfillment

Project background

Order consolidation became the bottleneck

A large e-commerce fulfillment operation was picking thousands of small items per hour, but manual order consolidation —matching picked items to the right order for packing —could not keep up. With hundreds of SKUs and multi-item orders, pickers spent more time walking between put-walls than picking.

Client challenges

The consolidation problem

• Thousands of small items to consolidate into orders every hour
• High SKU count with multi-item orders
• Manual put-walls consumed floor space and walking time
• Order accuracy errors drove returns and repacking

Our solution

Sorting into the third dimension

We installed a 3D put-wall sorter with multi-level vertical slots and closed-loop circulation. Picked items enter the loop, are verified by multi-side scanning cameras, and are inserted automatically into the correct order slot —consolidating orders without manual walking.

• 100+ multi-level vertical slots for high order counts
• Closed-loop circulation with automated slot assignment
• 3-/5-side scanning verification for order accuracy
• WCS integration with order and slot management

Performance outcome

Consolidation caught up with picking

• Up to 6,000 orders/h consolidated automatically
• ≥9.99% consolidation accuracy with multi-side verification
• Floor space freed by moving consolidation vertical
• Reduced manual walking and order-error costs