Loop Cross-Belt Sorting Hub

Project background

A hub running out of sorting hours

The customer's express operation was sorting several tens of thousands of parcels nightly by hand and with an aging pop-up sorter. Every parcel had to clear the hub before the last dispatch departure, and the gap between volume and sortation capacity was shrinking every month.

Client challenges

What had to change

• Clear the full nightly volume inside the dispatch window
• Handle mixed parcel sizes including soft bags and irregular shapes
• Keep running 7×24 through peak seasons without line downtime
• Integrate sortation data with the existing warehouse software

Our solution

A loop cross-belt sorter, turn-key

We engineered and installed a loop cross-belt sorter sized to the hub's nightly peak, with multi-lane DWS-equipped induction feeding the ring at full capacity. Belt and roller conveyors connect inbound, induction, discharge chutes and take-away, and our WCS drives destination assignment with full integration to the customer's WMS.

• Loop length and chute count configured to destination network
• Multi-lane DWS induction for automated data capture
• Belt / roller conveyor network for infeed and take-away
• WCS with WMS interface, on-site commissioning and training

Performance outcome

Peak volume cleared, every night

• Up to 10,000 pcs/h sortation capacity through the dispatch window
• 99.99% sorting accuracy with multi-side verification
• Mixed parcel formats handled without jams or damage
• 7×24 continuous operation through peak seasons