Sweeper Sorter Case Study: Cost-Effective Distribution Automation
Case study of a mid-size retailer that deployed a two-stage sweeper sorter with wave picking to reduce manual sortation and labor costs.
After moving to a larger facility, the retailer replaced manual sortation of small items with a bi-directional sweeper sorter system. The solution uses wave picking to batch orders, then routes them through 20- and 80-destination sorters for final separation. Results include a 40 percent reduction in annual labor costs, ROI in under two years, and improved order accuracy.
Two-stage sweeper sorter with wave picking replaced multiple manual touchpoints
Labor reduced from 27 to 16 full-time equivalents with shorter workdays
40 percent annual labor cost reduction achieved with ROI in less than two years
Accuracy improved, supporting higher customer retention and new business
Compact footprint suited mid-size distributors previously deterred by automation cost
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