In 2007, SDI installed a Sortrak unit sorter for a major apparel retailer to process
e-commerce orders. The original sorter was designed with a single induction
platform with room to accommodate 8 inductors, 173 chutes and 57 packstations.
The machine has the capability to process a maximum of 14,400 units/trays per
hour.
In the operation, workers pick waves of product in bulk where
they are conveyed to the sorter induction station. Inductors place the product
on an empty tray where it is sorted to the proper chute and chamber [SDI worked
closely with the client to design each chute with an 'up & down' chamber to double
the number of orders than can be sorted in a wave while saving valuable floor
space]. The system sorts 10 orders at a time into a chamber. When a chamber
is full, a light tells the packer to open the chamber and perform the final sort
down to unique orders in the pack station cubbyholes. The order is then packed
into a carton or envelope, labeled, and sent to shipping.
In 2011,
an average of 19K orders and 80K units were packed per day. Peak days were 34K
orders and 140K units. A second induction platform will be added which will
double the mechanical capacity of the machine to 28,800 units/trays per hour and
the sorter will be increased in size with 45% more chutes & packstations.
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