What is automatic sorting?
Automatic sorting means a sorting machine automatically assembles your orders based on your order lists. Incoming goods (from suppliers or returns) can also be automatically sorted according to pre-set warehouse criteria.
When does automatic sorting become relevant?
The answer: when you would otherwise need to hire too many people to bring your picking and sorting process to the desired level. Ultimately, it’s a matter of calculation (we help you with an ROI scan).
A sorting machine means: increased capacity, speed, and accuracy, and reduced labor costs and error margins. As a rule of thumb, DistriSort uses a lower limit of 2,500 items per hour (depending on the type of sorter and items). The upper limit is around 34,000 items per hour (24/7).
The benefits of automatic sorting
We've listed the benefits of automated sorting technology for you once again:
- Sort larger volumes (up to 34,000 UPH)
- Error-free sorting (= fewer returns)
- Faster sorting
- Labor cost savings
- More efficient picking (batch picking)
- Accurate inventory management
- 24/7 operation
- Integration with existing WMS/ERP
- Real-time data and traceability
- Higher throughput on a smaller footprint
- Handle demand fluctuations
- Less dependency on labor availability
- Improved employee health and job satisfaction
A sorting solution for every industry
Once automatic sorting becomes relevant for your business, the next question is: Which type of sorting machine best fits your operation? To help you decide, you can use our Sorting Assistant. In just 4 clicks, you’ll receive a recommendation that fits your business.
DistriSort has extensive international experience in sectors such as fashion, e-commerce, 3PL, books, parcel & post, and pharmaceuticals (among others). You can benefit from all that experience by consulting our experts, free of obligation. They understand the specific needs, challenges and solutions for your industry.
And there is more...
Automatic sorters can handle a wide range of products. The shape and weight of the items you want to sort play a key role in choosing the right sorter.
For example, a spherical item tends to roll or shift, requiring a different type of sorter than a square cardboard box.
The weight of an item is also crucial. Ejecting a 5-gram envelope is much easier than handling a 15 kg box.
Additionally, the chutes must be built to withstand repeated impacts from heavy items like those 15 kg boxes, or even heavier.
Sorting Machines
The Split Tray sorter, Push Tray sorter, and Cross Tray sorter. There are three different types of sorters, each with proven technology, a successful international track record, and low maintenance requirements. All three can handle inbound, outbound, and return flows on the same machine. While they may overlap in some areas, their unique characteristics make the difference.
The favorite in garments, post (mixed and rest mails), books/magazines due to its high throughput (up to 34,000 UPH) and suitability for a wide product range. Thanks to its patented opening mechanism, sorting and stacking into a box or crate can be done in a single run.
A top performer in logistics. It features dual-sided ejection and double exits on a relatively small footprint. Depending on the configuration, it offers a capacity of 8,800 to 24,000 UPH. It is used in 13 countries by major players in shoes, sport goods and toys.
Ideal for sorting a wide range of products and items with an unusual shape (round, tubular, conical, etc.) or lightweight items. With four raised edges, items stay securely in place. It can sort directly into boxes, mailbags, crates, or bins. With a capacity of 3,000 to 17,000 trays per hour, it’s perfect for automotive spare parts, jewelry and watches, accessories, pharmaceutical/supplements, parcel/packages, consumer goods/drugstore, multimedia and small electronics.
DistriSort has its own in-house IT department, where the software is developed to ensure that our sorters can be seamlessly connected to any existing WMS or ERP system, regardless of the provider. DistriSort takes full responsibility for a flawless software integration.
Why choose DistriSort?
- Our knowledge and international experience mean you get honest, expert advice — even if that means telling you when automation isn’t the right choice. Every recommendation is grounded in real-world experience from your industry.
- DistriSort is a system integrator offering turnkey sorting solutions — from complete sorting concepts to complementary applications within existing operations.
- Our goal is to optimize your logistics process and contribute meaningfully to achieving your business objectives.
FAQ Automatic Sorting
Specific questions or can't find your query? Contact us!
We help you with a realistic ROI scan. The payback period depends on your sorting volumes and labor savings. On average, the investment in an automatic sorting solution can be recovered within 12 to 24 months — in some cases, even less than a year.
Yes. DistriSort ensures that your existing WMS and/or ERP software is seamlessly connected to the sorter’s software.
Sorting machines vary in size. The available floor space and ceiling height are key factors in choosing the right type of sorter.
Yes we can.
DistriSort specializes in loop sorters for high-throughput single item sorting. Our sorters are ideal for: fashion, e-commerce, 3PL, books, parcel & post, pharmaceuticals, small electronics, and more.
Yes. In an existing setup, you can choose to add a sorter to speed up and improve the sorting process. In this case, the sorter is tailor-made to ensure seamless integration into your current intralogistics system — for example, as an extension to a G2P system.
Yes. The picking process will change, and adjusting your storage layout can lead to efficiency gains. Extending sorting hours may require working in shifts, and supervision of the sorter will be necessary.
There’s something for everyone. DistriSort works with trusted suppliers to ensure consistent quality. We’re happy to help you find what’s relevant for your business. Below is a general overview of commonly used peripheral equipment:
- No-read belt: Automatically returns unreadable items (e.g., without a barcode) to the input platform, allowing them to be re-entered immediately.
- Container tippers: Enable fast and easy emptying of containers. Commonly used by large 3PLs and postal services.
- Singulator: Automatically separates products from the tipper, synchronizing product input with the sorting machine.
- Automated infeed: Often used in combination with tippers, eliminating the need for additional personnel.
- Robotic infeed: All our sorting machines are ‘robot-ready’.
- Conveyor systems: For inbound and outbound transport. The ‘Box Return Conveyor’ keeps the workspace clear of empty boxes.
- Weighing belts: Determine the weight of an item upon entry or exit of the sorting machine.
- Labeling machines: Automatically apply an ID or shipping label to boxes.
- Carton sealers: Automatically close boxes and apply sealing tape.
- Chute pitch reducer: Increases the number of exits by approximately 40% within the same floor space.