Cross Tray Sorter: High-Speed Sorting for Non-Conveyable Items

Technology Overview

EuroSort's Cross Tray Sorter represents a significant innovation in the field of automated sortation, specifically targeting a category of items that has traditionally challenged high-speed sorting systems: non-conveyable, fragile, and lightweight goods. Many conventional sorters struggle with items that cannot be easily conveyed on belts or that require gentle handling. This technology aims to disrupt the industry by providing a viable high-speed solution for these problematic items. The core of the innovation lies in its divert mechanism—a positive mechanical system that can sort items to both the left and right, without relying on expensive and complex motors installed in each individual carrier tray. This approach allows the system to achieve throughputs of up to 9,600 items per hour while handling products that were previously considered "unsortable" at such speeds.

How It Works

Core Principles

The system operates as a tilt-tray or cross-tray sorter where items are carried in trays. The key differentiator is the discharge mechanism. Instead of each tray having its own motorized tilt mechanism, a centralized, positive mechanical divert system interacts with the trays as they pass by. This external mechanism physically engages with the tray to tip it to the left or right, discharging the item into the appropriate sortation chute. This design simplifies the individual carriers and centralizes the actuation.

Key Features & Capabilities

Handling of Challenging Items: The primary capability is sorting "non-conveyable, fragile, and lightweight items." This includes bags of clothing, poly-mailers, padded envelopes, and other items that do not slide easily on belts or are easily damaged.

Simple, Motorless Carrier Design: By avoiding expensive motors and complex electronics in each tray, the system aims for higher reliability, lower carrier cost, and reduced maintenance compared to traditional tilt-tray sorters.

Bidirectional Positive Mechanical Divert: The ability to sort both left and right with a robust mechanical action provides sorting flexibility and ensures reliable discharge even for lightweight items that might not slide off a gently tilted tray.

Advantages & Benefits

The main advantage is opening high-speed automation to a new class of products, significantly expanding the scope of what can be efficiently sorted in facilities like e-commerce fulfillment centers. The simplified carrier design promises lower capital cost per carrier and potentially higher system uptime due to fewer points of failure. High throughput for delicate items enables faster order processing and reduces manual handling, improving both efficiency and product safety. The technology solves a recognized industry problem, offering a specialized tool where general-purpose sorters fall short.

Implementation Considerations

As a disruptive technology, thorough testing with the specific item mix of a facility is crucial to validate performance claims. The mechanical divert system, while simpler at the carrier level, is a critical centralized component whose reliability must be exceptional. The system is specialized; it may not be the optimal choice for facilities that primarily handle standard, conveyable cardboard boxes.

Use Cases & Applications

Ideal For

The Cross Tray Sorter is ideal for e-commerce operations with a high proportion of soft goods (apparel, bedding), fragile items, and shipments in polybags or non-rigid packaging. It is also suitable for parcel services handling a large volume of lightweight, irregular parcels.

Conclusion

EuroSort's Cross Tray Sorter introduces a compelling and specialized solution to a persistent challenge in logistics automation. By rethinking the tray discharge mechanism with a centralized, positive mechanical approach, it targets the high-speed sorting of items that have historically resisted automation. For businesses whose product mix is dominated by non-conveyable or fragile goods, this technology could represent a breakthrough, enabling labor savings and throughput levels previously unattainable. While its specialized nature means it is not a universal sorter, its potential impact on sectors like e-commerce fashion is significant. Adopters should conduct detailed pilot testing to ensure the system meets their specific item-handling and throughput requirements.