High-Density Narrow-Belt Distribution Center

Project background

More destinations, same floor space

A distribution center serving retail and e-commerce routes needed to expand its destination count, but the warehouse footprint was fixed and every square meter was already in use. The answer had to fit the existing building —not the other way around.

Client challenges

Constraints on the table

• Dozens of new destinations in a very limited footprint
• Mixed small and medium parcels including soft packaging
• Minimal disruption to a live warehouse during installation
• Low parcel damage rate for fragile and soft items

Our solution

A narrow belt sorter that fits

We designed a high-density narrow belt sorter with angled divert units, packing the required destinations into the available footprint. DWS was integrated at infeed for automated data capture, and the modular sections were pre-assembled so the line could be installed around the live operation.

• High destination density in a compact footprint
• Angled belt divert units for gentle, controlled discharge
• DWS integration at infeed for dimension, weight and barcode
• Modular sections for fast, low-disruption installation

Performance outcome

Density without compromise

• Required destination count delivered inside the footprint
• Gentle handling with low parcel damage rate
• Live warehouse kept running through installation
• Modular design ready for future destination expansion