Developing an Effective Sortation System
Framework for evaluating and implementing sortation systems in distribution operations. Covers needs analysis, automation thresholds, and equipment selection across induction, sortation, and aftersort stages.
This white paper outlines a five-step process for designing sortation systems that handle complex SKU mixes and high throughput demands. It details operational constraints to audit, automation decision criteria, and technology options for each stage of the sortation process. The guidance emphasizes modular, pre-engineered designs that support future scalability and integration with existing facility layouts.
Sortation should be designed as an integrated system component rather than an add-on process
Automation is justified when throughput exceeds 3,600 items per hour and accuracy targets reach 99.9%
System planning requires auditing product weight, carton size, throughput rates, noise limits, and site constraints
Effective designs address induction, sortation, and aftersort stages with coordinated equipment and controls
Modular pre-engineered components enable faster installation and easier future expansion
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