Automated Sortation Solutions for High-Speed, Accurate Order Fulfilment
Boost throughput, reduce errors, and optimise your distribution network with advanced sortation technology
sortation for warehouses
Sortation and the routing of products is a crucial element for most warehouses and eCommerce fulfilment centres. Whether this is a simple routing change or high-speed sortation prior to despatch, there is a solution to suit all applications.
Utilising various triggers such as carrier labels, barcodes, RFID, LPN (Licence Plate Number), weight, size, colour, etc. running alongside a WMS system, making intelligent decisions to control the hardware.
sortation Challenges
- Manual sortation bottle necks
- Rising labour costs
- Error rates
- Peak season strain
Benefits of Automated Sortation
- Labour Reduction: Fewer manual touches.
- Speed: Handle peak volumes without extra staff.
- Accuracy: Lower returns and mis-shipments.
- Scalability: Modular design for future growth.
Improving Throughput
Sortation and the routing of products is a crucial element for most warehouses and eCommerce fulfilment centres. Whether this is a simple routing change or high-speed sortation prior to despatch, there is a solution to suit all applications.
Utilising various triggers such as carrier labels, barcodes, RFID, LPN (Licence Plate Number), weight, size, colour, etc. running alongside a WMS system, making intelligent decisions to control the hardware.
Sortation Types
Low Speed sorters
Low speed sorters provide a reliable and cost-effective way to divert products accurately within conveyor systems, making them ideal for order consolidation, routing to multiple destinations, and controlled throughput environments. CSL Automation designs and integrates low speed sortation solutions tailored to your product range, layout, and operational requirements.
Options Include:
Interroll Belt Transfer • Uni-XU Chain/belt transfer • Itoh Denki F-RAT
Mid-Speed Sorters
Mid-speed sorters offer higher throughput and greater flexibility than low speed systems, making them well suited to busy distribution, ecommerce, and fulfilment operations where accuracy and efficiency are critical. CSL Automation designs and delivers mid-speed sortation solutions that balance performance, footprint, and long-term reliability.
Options Include:
Interroll HPD • Intralox DARB • Uni-XU Switch Sorter • Mod Sort
High-Speed Sorters
High-speed sorters are designed for operations with demanding throughput, tight cut-off times, and a need for consistent, accurate destination sorting. Ideal for large-scale ecommerce, parcel, and distribution environments, CSL Automation’s high-speed sortation solutions are engineered to deliver maximum performance, reliability, and scalability.
Options Include:
Euro Sort (Cross Tray) • Euro Sort (Split Tray) • Intralox ARB • Interroll Split Tray Sorter • Interroll Crossbelt Sorter (Horizontal) • Interroll Crossbelt Sorter (Vertical)
Crossbelt sorters
Crossbelt Sorters deliver fast, accurate, and gentle product handling for high-volume operations. Capable of sorting up to 80,000 items per hour with 99.9% accuracy, they handle a wide range of package sizes and weights while offering scalable, modular designs to grow with your operation.
Flow Sort
Flow Sort offers modular, plug‑and‑play sortation that integrates seamlessly into conveyor systems. It provides gentle, flexible diverting for a variety of layouts, handling up to 6,000+ items per hour and loads up to 35 kg, delivering scalable, cost‑effective sortation that grows with your operation.
Modsort systems
ModSort (Modular Sort) provides flexible, energy‑efficient sortation with integrated transfer and divert modules that easily link into new or existing conveyor systems. Designed for mid‑rate parcel handling (up to ~3,000 cases/hour in typical configurations) and loads up to ~22 kg per package, ModSort delivers reliable on‑the‑fly diverting and scalable modular design for dynamic distribution and fulfilment environments.
Intralox DARB
DARB Sorters use Activated Roller Belt (ARB) technology to deliver precise, high‑efficiency sorting in compact footprints. They gently and accurately divert and orient products bi‑directionally or at 90° with minimal maintenance, handling varied items at rates up to ~5,100 cases/hour in typical configurations, ideal for tight spaces or complex routing in fulfilment and distribution environments.
Why automate sortation?
Manual sortation struggles with rising volumes, labour scarcity, accuracy demands, and peak season spikes. Automated sorters provide consistent speed, precision, and flexibility—minimising mis-sorts, reducing manual touches, and enabling data-driven control across your fulfilment or distribution operations.
Key outcomes:
- Higher throughput: 2,500–35,000+ items/hour, engineered to your SKU mix and destination count
- Accuracy: Up to 99.9% precision with barcode/RFID, vision, and robust controls
- Labour savings: Fewer manual touches and safer operations
- Scalability: Modular designs and destination expansion without disruption
Our Approach
We deliver sortation as a complete solution—from application engineering to lifecycle support.
- Survey & Data Capture – SKU profiles, packaging types, arrival patterns, destination rules, peak/average volumes
- Concept & Simulation – layout options, throughput modelling, accumulation & recirculation logic
- Mechanical & Controls Design – sorter selection, conveyor interfacing, scanning/dimensioning, WMS/WCS integration
- Build, FAT/SAT & Commissioning – staged testing, on-site handover, training, run-rate ramp-up
- Service & Spares – preventive maintenance, remote diagnostics, upgrades and expansions
Typical Applications
- eCommerce Fulfilment Batch picking to destination sort, order consolidation, and intelligent exception handling—built for peak volumes.
- Parcel Hubs & Cross-Dock High-speed parcel routing by service level, size, or zone; efficient recirculation for no-read/duplicate labels.
- Retail Distribution Store-based allocation from totes/cartons; stable throughput with minimal damage and predictable waves.
- Manufacturing & Kitting – Component kitting and line-side sequencing; accurate routing to workstations with real-time control.
Integration & Data
- Identification: Barcode (1D/2D), RFID, and vision systems with multi-read strategies and no-read handling
- Dimensioning & Weighing: Inline measurement for compliance, charge-back accuracy, and sorter protection
- WMS/WCS & Middleware: Real-time handshakes, destination logic, exception routing, and performance reporting
- Dashboards & Analytics: Live KPIs (throughput, accuracy, no-reads, recirculation rates), downtime tracking, and maintenance alerts
Discuss your automation Project
Thank you for your interest in CSL Automation. As one of the UK’s leading conveyor and automation integrators, we can help design and install a system to help you take your business to the next level.
Start your automation journey today.
Explore our solutions
Automated Returns
Multi-Floor Handling
Order Packing
Order Picking
Pallet Handling
Product Sortation
Product & Material Transit
Stock Replenishment
Our Case Studies
Product Sortation - Frequently Asked Questions
Which sorter is best for mixed SKUs and fragile items?
Cross-belt is typically preferred for accuracy and gentle handling; sliding shoe is excellent for speed with robust cartons. We validate with your product mix.
How do you handle no-reads and duplicate labels?
We implement multi-read scanning, exception lanes, manual QA points, and recirculation logic with WMS/WCS rules.
Can you integrate with our WMS/WCS?
Yes. We provide real-time handshakes, destination mapping, middleware if required, and dashboards for monitoring.
What maintenance is required?
Preventive maintenance plans include inspection, belt/chain service, calibration, and software health checks. We train your teams and can provide 24/7 support.
What floor space do we need?
Layouts are compact and modular; we design around your constraints and can use loop/recirculation strategies to reduce footprint while maintaining throughput.
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How accurate is automated sortation?
With good label quality and scanning, up to 99.9% accuracy is typical. Vision systems and QA/no read lanes further enhance reliability.
