When planning a new distribution centre (DC), the development process comprises analysing every logistical process before considering how the combination of technologies can be used to achieve the highest efficiency.
The right solution can be a number of technologies, as long as it meets the requirements of the individual DC. There is no one-size fits all.
Sometimes the solution can be a pouch sortation system, sometimes a goods-to-person (GTP) system, sometimes a combination
And sometimes the goods fulfilment solution of choice can be based on a loop sortation system (the tilt-tray or cross-belt system technologies).
Loop sortation can be ideal for a warehouse or DC with high sortation needs, where the goods come in and quickly leave again – for example, when you need the flexibility to ensure prompt stock replacement for a number of shops.
Unlike the shuttle system, the loop sortation system has no real buffer. The loop sorter is therefore often applied with the main purpose of cross-docking, sorting items and sorting packed orders for shipment.
With a good system design, however, loop sorters can also be configured to handle all inbound flow and distribution between the processes as well as outbound flow.
This means using the sorter as backbone to enable flexible and seamless distribution to and from all internal processes inside the overall DC system.
In making such a configuration of combined technologies lies the possibility to use the loop sorter system to increase efficiency in areas not usually directly linked to the sorter.
Using a loop sorter as a means for process connections enables usage of the one and same sorter several times per circulation – with flexible and seamless distribution to and from all processes.
It could be called a system-wide approach to warehousing and distribution because it allows a distribution centre to link all its logistical process with one single system.
The size and complexity of today’s modern DCs means that flexibility has become the key to streamlining the material flow.
By using a high-speed loop sorter as the backbone, the sortation system can be used to link all of the DC’s core operational processes and to simultaneously sort multiple flow routes from in-feed through to dispatch.
The loop sortation system’s design flexibility already begins with the sorter’s ability to accept loose-loaded cartons. Sometimes at this point in the material flow, a Warehouse Management System (WMS) label is automatically applied to each carton before it is entered into the system.
After induction to the loop sorter, any carton can be routed to any area within the DC, thus allowing a single material handling system to quickly and accurately handle different flow patterns simultaneously.
Using a modern loop sortation system-based as backbone for the material handling system design gives an opportunity to link different storage areas within a DC consisting of systems such as:
In a multipurpose DC design, a loop sorter could potentially complement a shuttle system, ensuring the warehouse can optimally handle both a large inventory and high sortation needs.
Also, by using a loop sorter as backbone, the DC has the option to recirculate items to increase the overall system-elasticity.
A distribution centre (DC) needs technology with the flexibility to ensure prompt stock replacement for a number of shops across various countries. Ideally the combined technologies should be used to achieve the highest efficiency, including helping to increase efficiency in areas not usually directly linked to the sorter.
Now imagine a multipurpose system integrating a high bay pallet warehouse with automatic palletisers and depalletisers, buffer storage with dynamic carton locations, automated GTP, light goods conveyors and automated sortation.
The loop sortation system could be configured to handle all inbound and outbound flow and distribution between the DC processes.
Automated inbound material flows with loop sorter as backbone
Excess cartons from any of the processes can be routed to the mini-load Automated Storage and Retrieval System (AS/RS) to be used as replenishment stock.
The flexibility starts with the sorter’s ability to accept loose-loaded cartons from containers or pallets. After induction, any carton can be routed to any area within the DC, allowing a single loop sortation system to quickly and accurately handle different flow patterns simultaneously.
A well-designed loop sorter-based system can provide the ability to respond to rapid changes in item profiles as well as to vary the system capacity to reflect seasonal changes in demand.
If greenfield, the material handling system designer is able to prepare the design for any future expansion in capacity required to support the increased growth and sophistication of the e-commerce sector.
In addition a cleverly designed sortation system can be applied with discharge chutes that help reduce the footprint of the sorting area – a factor that has become increasingly valuable with the high price of land and hence the cost for establishing a DC.
Also, the seamless integration with the appropriate digital services gives system-wide visibility of workflows in the entire system with precise control of individual processes.
Here, n addition to the traditional SCADA overview, and with use of today’s tools for big data mining, streamed data can be enriched and filtered to secure the quality of the data, which is aggregated and prepared for simple visualisation. This type of insight into the performance of a material handling system enables the build-up of a historical record for future investigations and learnings across system processes to enable the maintenance, operational and management levels to make better informed decisions.
The integration of processes enables usage of a loop sorter several times per circulation with flexible and seamless distribution – both to and from all processes. The sortation system can be used to link all of the core operational processes and simultaneously sort multiple flow routes from the in-feed through to dispatch. Using the sorter as backbone will enable a more flexible and seamless distribution to and from all processes inside the overall DC system.
In today’s world, distribution centers have access to vast amounts of data, which serve as a powerful resource for enhancing sortation throughput. Storing this data not only offers valuable insights into the system’s current performance but also creates a historical record that can be utilised for future analysis and learning.
