Sortation Conveyors - Applications & System Design Tips

Sortation conveyors are an essential component of material handling systems used to efficiently sort and distribute items based on their destination or specific criteria. They can be found in various industries, including e-commerce, logistics, postal services, and manufacturing. Here are some applications and system design tips for sortation conveyors:

Applications of Sortation Conveyors:

1. Order Fulfillment: Sortation conveyors are commonly used in e-commerce warehouses and distribution centers to process and sort orders for shipment. They can handle a large volume of products and direct them to the appropriate outbound lanes or loading docks based on customer orders.

2. Parcel Sorting: Sortation conveyors are used in postal and courier companies to sort packages and parcels based on their destination addresses, sizes, or services. They can scan barcodes or utilize other identification technologies to determine the sorting criteria and divert the items to the corresponding chutes or bins.

3. Baggage Handling: Airports and transportation hubs often employ sortation conveyors to efficiently handle and process luggage and bags. The conveyors can automatically sort bags based on flight destinations, ensuring accurate routing and minimizing delays.

4. Manufacturing: Sortation conveyors play a crucial role in manufacturing processes, where products need to be sorted based on their characteristics or specific criteria. They can divert items to different production lines or workstations based on production requirements, quality control, or customization options.

System Design Tips for Sortation Conveyors:

1. Throughput Capacity: Determine the required throughput capacity of the sortation conveyor system based on the expected volume of items to be sorted per hour or shift. Consider factors such as peak periods, future growth, and potential system expansions.

2. Sorting Method: Choose the appropriate sorting method for your specific application. Some common sorting methods include diverters, pushers, pop-up wheels, tilt trays, sliding shoes, and conveyor belt merging.

3. Integration with Identification Systems: Integrate identification systems such as barcode scanners, RFID readers, or vision systems to efficiently identify and track items for sorting purposes. This ensures accurate diversion and minimizes errors.

4. Conveyor Speed and Gap Between Items: Determine the optimal conveyor speed and gap between items to allow sufficient time for diverting or merging operations. Consider the size, weight, and fragility of the items being sorted to avoid jams or damage.

5. System Flexibility: Design the sortation conveyor system to accommodate different types and sizes of items. Incorporate adjustable guides, lane dividers, or modular designs that can be easily reconfigured as product requirements change.

6. Maintenance and Serviceability: Consider ease of maintenance and serviceability during system design. Include access points, spare parts availability, and preventive maintenance schedules to minimize downtime.

7. Safety Considerations: Ensure that the sortation conveyor system complies with relevant safety standards and regulations. Implement safeguards such as emergency stop buttons, safety interlocks, and proper guarding to protect operators and prevent accidents.

By considering these applications and system design tips, you can design and implement an efficient and reliable sortation conveyor system that meets your specific sorting.