DPD Warszawa - Poland Logistics Center Parcel Sorting Automation

Project Overview

DPD Warszawa, a key player in Poland’s parcel and express logistics sector, sought to revolutionize its parcel handling operations at its Warsaw logistics center. Facing the demands of high-volume logistics and the need to handle diverse parcel types—from small polybags to larger, fragile items—the company needed a sorting solution that combined efficiency, precision, and adaptability.

The core objectives were to optimize parcel flow, ensure gentle handling of a wide range of items (including fragile and high-friction products), and establish a future-proof system that could scale with evolving operational needs. Additionally, DPD aimed to reduce operational costs through energy-efficient, low-maintenance technology while setting new standards for sorting efficiency in the Polish logistics market.

To achieve these goals, DPD partnered with BEUMER Group to implement the BG Line Sorter—a state-of-the-art system that merges the simplicity of traditional line sorters with the precision of high-speed cross-belt technology. This integration was designed to address the unique challenges of high-volume parcel sorting while delivering reliability and scalability.

Technical Solution

BEUMER BG Line Sorter with Active Slat-Belt Technology

At the core of the solution is the BG Line Sorter, which integrates cross-belt technology with active slat-belt design to enable gentle and precise parcel handling. The active slat-belt mechanism provides consistent contact and control over parcels, regardless of size, weight, or surface properties—making it suitable for small polybags, larger packages, fragile items, and high-friction products. This technology minimizes damage risk while ensuring accurate sorting, a critical requirement for DPD’s diverse customer base.

Key Features

The Active Slat-Belt Technology is a standout feature, providing gentle yet precise handling of diverse parcel types. This ensures that even fragile and high-friction items are sorted without damage, expanding DPD’s capability to handle a wider range of customer shipments.

The system’s high throughput range (1,500-10,000 items per hour) makes it versatile enough to handle both daily operations and peak demand periods, ensuring consistent performance regardless of parcel volume.

The modular design offers exceptional space efficiency, fitting within the existing logistics center footprint while allowing for future expansion. This adaptability ensures the system remains relevant as DPD’s business needs evolve.

Low-maintenance components and energy-efficient operation reduce operational costs, from maintenance expenses to utility bills, delivering long-term value beyond initial implementation.

The integration of traditional line sorter simplicity with cross-belt precision combines user-friendly operation with high-performance sorting, minimizing training requirements while maximizing efficiency.

Results & Benefits

The BG Line Sorter has enabled DPD Warszawa to achieve reliable sorting throughput of 1,500-10,000 items per hour, significantly optimizing parcel flow and reducing processing times. This high throughput ensures the logistics center can meet the demands of high-volume express logistics.

The Active Slat-Belt Technology has eliminated damage risks for diverse parcel types, including fragile and high-friction items. This has improved customer satisfaction by reducing shipment damage and enhancing the reliability of delivery services.

Operational costs have been reduced through the system’s low-maintenance design and energy-efficient components. Fewer maintenance requirements mean less downtime and lower upkeep expenses, while reduced energy consumption cuts utility costs.

The modular, scalable design has provided DPD with a future-proof solution. The company can easily reconfigure or expand the system to accommodate growing parcel volumes or changing operational needs, avoiding the need for costly new infrastructure.

By implementing the BG Line Sorter, DPD Polska has set new standards for parcel sorting efficiency in Poland’s logistics sector. The solution has enhanced the company’s competitive position by delivering faster, more reliable, and cost-effective parcel handling.

Challenges & Solutions

DPD’s primary challenge was handling a diverse range of parcel types—from small polybags to larger, fragile items—with consistent precision and without damage. The solution was BEUMER’s Active Slat-Belt Technology, which provides gentle, controlled handling for all parcel categories, ensuring accuracy and minimizing damage.

A second key challenge was meeting the high-volume demands of express logistics while maintaining operational efficiency. The BG Line Sorter’s 1,500-10,000 items/hour throughput capacity directly addressed this, optimizing parcel flow and enabling the center to handle peak periods without bottlenecks.

The third challenge was building a future-proof system that could adapt to evolving operational needs, such as growing parcel volumes or changing shipment profiles. The solution’s modular design allows for easy reconfiguration and expansion, ensuring the system can scale with DPD’s business without major infrastructure investments.

System Integrator

BEUMER Group served as the system integrator and technology provider for the project, delivering its BG Line Sorter as the core solution. The company’s expertise in high-speed sorting systems and parcel handling technology was critical to designing a solution tailored to DPD’s specific needs.

BEUMER’s responsibility included system design, equipment supply, installation, and integration with DPD’s existing logistics infrastructure. The company’s focus on modularity, efficiency, and reliability ensured the solution aligned with DPD’s goals of improving sorting performance, reducing costs, and enhancing customer satisfaction.

The successful implementation of the BG Line Sorter reflects BEUMER Group’s leadership in parcel sorting technology and its ability to deliver solutions that meet the unique challenges of express logistics. The partnership between DPD Warszawa and BEUMER Group has resulted in a best-in-class sorting system that sets new efficiency standards in Poland’s logistics market.