Patented Dual Split Tray (Bomb Bay) Sorter with Batch Induction

Technology Overview

This technology details a specific application of EuroSort's patented Dual Split Tray Sorter, integrated into a streamlined workflow for apparel and accessories e-commerce fulfillment. The system acts as a critical link between automated storage and the final packing stage. Instead of sorting discrete items from a general pick area, this setup receives batch-picked items delivered automatically in totes from an Automated Storage and Retrieval System (AS/RS). Operators then induct these batched items onto the sorter, which efficiently sorts them into individual customer orders, with the output funneled directly into outbound shipping cartons. This represents a highly automated flow from storage to shipment, designed for high-volume, fast-turnaround operations.

How It Works

Core Principles

The core principle remains carrier-based sortation with bottom-opening trays. The innovation in this workflow is its integration point: it is fed by totes arriving from an AS/RS, containing items picked in batches for multiple orders. The system includes logic (Batch Divider) to manage the transition from batched input to sorted output for individual orders.

Key Features & Capabilities

AS/RS Integration: A key feature is its designed integration with an upstream Mini-load or similar AS/RS. This creates a seamless automated material flow where storage, retrieval, and sortation are connected, minimizing manual transport and handling of inventory between processes.

Batch Divider Functionality: This feature is crucial for processing batch-picked work. It helps the sorter's control system logically separate items from different pick batches, ensuring accurate sorting even when inducting from mixed totes and maintaining order integrity.

Direct-to-Carton Funneling: The custom chutes are engineered not just to collect items, but to guide them directly into the shipping carton. This eliminates an extra transfer step (e.g., from a chute to a tote to a carton), streamlining the packing process and potentially reducing labor and touchpoints.

Advantages & Benefits

The primary benefit is creating a highly efficient, continuous flow from the AS/RS to the shipping dock. It reduces walking and handling for packers, minimizes errors in order assembly, and significantly speeds up the order cycle time. Integrating sortation with AS/RS leverages the strengths of both technologies: high-density storage/retrieval and high-speed order consolidation. This leads to greater overall facility throughput and improved scalability for peak seasons.

Implementation Considerations

This is a system-level integration project. The sorter must be precisely synchronized with the AS/RS's output rate and tote delivery schedule. The manual batch induction process remains a potential bottleneck and requires trained operators. The layout must accommodate both the AS/RS interface and the packing stations with cartons at the sorter discharge. The system is optimized for a specific type of goods (apparel/accessories) and a batch-pick order fulfillment model.

Use Cases & Applications

Ideal For

This integrated solution is ideal for large-scale, automated e-commerce fulfillment centers for fashion retailers that have already invested in or are planning an AS/RS for small item storage and utilize batch-picking strategies.

Performance Metrics

The key throughput metric remains up to 14,400 items per hour. Additional relevant metrics include the induction rate (items per hour per operator), order accuracy rate, and the reduction in pack station labor time due to the direct-to-carton process. The system's value is amplified by its role in an integrated automated workflow.

Conclusion

EuroSort's Dual Split Tray Sorter, when integrated with an AS/RS and configured for direct-to-carton discharge, represents a powerful, high-performance solution for modern apparel e-commerce fulfillment. It effectively automates the critical order consolidation and packing interface, which is often a major bottleneck. For companies operating at scale with an automated storage backbone, this sorter technology can deliver significant gains in speed, accuracy, and labor efficiency, providing a competitive edge in fast-fashion and online retail logistics.