The challenge
A leading logistics client needed a high-speed parcel sorting system for multiple shippers. The solution had to roll out in two discrete phases, each handling up to 2,500 parcels per hour, with the central ship sorter capable of 5,000 parcels per hour. It required delivery to 10 sort locations, direct filling of Gaylord boxes, and reliable handling of boxed products plus both plastic and paper bags. Future expansion to auto-bagging was essential, together with real-time communication to the warehouse management system. Phase 1 needed to be fully live for peak season in just 10 weeks, with Phase 2 operational one week later.
The Automatica solution
Automatica delivered a tailored, modular system built around proven standard equipment to hit the tight deadlines. Phase 1 mechanical, electrical installation and commissioning were completed in three weeks, ready before Black Friday peak. Phase 2 followed post-peak in one week. The design combined robust 400V belt conveyors with high-speed 48V DC technology, networked through an industrial PC that handled middleware communication between the client’s host and Siemens PLC. At the core was an Intralox ship sorter engineered to cross-sort 5,000 parcels per hour at 90 metres per minute.
The results
The system launched on time, met every performance specification, handled peak volumes smoothly and reliably, reduced operational stress during the busiest period, and provided a clear, scalable platform for future auto-bagging integration.
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