Moving from manual to automated parcel sorting, or upgrading or adding new automated systems to an existing setup, can be a game changer. Automation has the ability to reduce expensive labor costs, improve the accuracy of shipments, and allow you to process more packages and parcels, among other benefits. Designing your automated parcel sorting system the right way, however, is critical to helping you achieve the highest return on your investment.
At ID Parcel & Mail Solutions our primary goal, when designing our Packet Parcel Sorting System (PPSS) for a customer, is to ensure it operates at peak efficiency and delivers the desired results. Here are the factors that we consider to achieve this goal:
Throughput refers to the number of pieces an automated parcel sorting system can sort per hour. Throughput is generally determined by the speed of the conveyor belts that make up the system, the gap spacing between the packages, the average length of the packages, and the maximum size length of package that will be processed. Significant contributors are also the method or methods of inducting packages on to the system and the processing speeds of the functions that will be incorporated into the automated parcel sorting system such as weighing or labeling packages.
So how do you achieve a desired speed with an automated parcel sorting system? It comes down to the features that you chose for the machine and how they align with your goals. It starts with the conveyor belts and the desired sorting technology. Higher speed belts will move packages along faster, and vice versa. Different sorting technologies will have different speed and package type capabilities such as multi directional sorter tables, active roller ball or activated roller belt sorting systems, package pushers or diverting arms, narrow belt sorters, shoe, tilt-tray or cross-belt sorters. More sophisticated Induction systems like semi-automatic induction feeders, as well as advanced barcode reading tunnels and weighing and dimensioning systems can all help process parcels at higher speeds and with more accuracy. For lower throughput requirements, less advanced technologies, that are also less costly, are used.
The types of packages, such as boxes, flats or polybags, that will be processed by your automated parcel sorting system will have a significant impact on the type of sorting system and features you choose for the machine. You’ll need to know the range of parcel dimensions, weights, materials, and the fragility of items that you will be running. If you’re running lightweight packages with uneven bottoms, for example, active ball or roller belt technology sorters or tilt-tray or cross-belt may be better suited to the application. However, packages with a reasonably firm and flat bottom can be sorted with many types of sorting solutions.
The space you have available to house an automated parcel sorting system, and the desired material flow within your facility, will drive the configuration of the machine itself. Staging of the parcels that require processing, and post sorting processing steps also determine the configuration of the machine in its space. For smaller spaces, the system conveyors may need to turn 90 degrees or even turn back around in a U shape. You’ll also want to consider future requirements including the potential to add onto the system as your operation and volume grows. You also may require additional technologies that need space to operate, such as a semi-automatic induction feeder. A good system design will consider all of these factors and can often utilize the available space effectively, even if it has limitations.
Determining the appropriate number of sort outlets or locations that your automated parcel sorting system will require will help to ensure the system is operating at peak efficiency. Having too few sort locations can lead to more passes of some packages through the system requiring additional time and labor, or extra manual sorting effort to finalize outbound packages. Too many sorting outlets that are underutilized will be a wasted investment in equipment and space. You’ll need to know how many is optimal for your current and expected volumes and sorting distributions over the payback period of your system. If volumes are low now, selecting a modular solution will allow expansion of the system at a reasonable cost when volumes do grow. Different sorting technologies and platforms can be easier or more difficult (expensive) to expand later.
Every sorting application will have different data requirements and every customer will have a different internal IT platform or technology for interfacing or integration. Part of achieving flexibility and reasonable cost is keeping these IT and data requirements simple but effective. Consider solutions that keep the business logic under customer control so that when business changes, the impact of the change is more likely to be under customer control versus the system manufacturer. However, some future changes may require changes to logic or features of the software that runs the system or interfaces with the sorting system users. It should be easy to adapt and reasonable in cost so that the useful life of the system is extended over the years.
For growing organizations, it can pay to design the full system to scale with the business, not just the number of sorting outlets. You’ll want to consider what components the system may need as orders increase and/or parcel types change. At ID Parcel & Mail Solutions, our Packet Parcel Sorting System (PPSS) is designed to be modular. As a result, components can easily be added to accommodate growth. With this type of system, we can add faster induction systems, barcode reading cameras for multiple views of the packages, sorter module or belt extensions and features fairly easily. And the software is designed for flexible adaptation, allowing for easy updating as needed.
At ID Parcel and Mail Solutions, our proficiency in designing and building efficient, flexible automated parcel sorting systems helps us achieve our client’s goals. We are capable of designing a small system solution for 1,000 packages per hour up to a system that processes packages at 10,000 pieces per hour. The critical factor is listening to a prospect, understanding their business objectives, educating on the options and costs, and then designing and delivering an automation system that delivers success to our customers with the return on investment expected.
