ID Parcel & Mail Solutions recently completed the design, build and installation of a large automated parcel sorting system for DHL eCommerce, a division of the world’s leading logistics company, DHL Group. The system was installed at their state-of-the-art Silver LEED certified 352,000 square-foot distribution center in Chicago, Illinois.
DHL eCommerce provides domestic and international parcel delivery for high-volume business customers. ID’s Packet Parcel Sorting System will support their cross-border shipping operations. They have successfully been operating the new system since March of this year.
Before the new automated parcel sorting system was put into service, DHL eCommerce was processing cross-border parcels using a semi-automated process. They were employing slower automation for weighing and dimensioning, and then shifted over to a manual process for parcel labeling and sorting. They wanted one system that could automate all of these steps.
Automated parcel sorting systems are highly valuable for cross-border parcel shipping as intelligent routing becomes even more important during international shipments. By increasing throughput speed and reducing human error, the Packet Parcel Sorting System will help DHL eCommerce fulfil tight delivery expectations across multiple time zones and increase their capacity at this site.
The data capture capabilities of DHL eCommerce’s new automated parcel sorting system also play a significant role during cross-border shipping. Accurately capturing barcode data, dimensions, weight, and destination details is a must for proper Final Mile Labeling, routing of packages and accurate billing for shipping. It also makes it easier to accurately track parcels, manage exceptions, and provide customers with accurate delivery updates across the various international touchpoints.
DHL eCommerce came to ID Parcel & Mail Solutions for this system in part due to our decades long relationship, but also because of our experience building automated parcel sorting systems for cross-border requirements in the past. DHL eCommerce’s new system uses a variety of design components that have been developed and tested in the field previously. This helped fast track the design and build process, and allowed DHL to receive equipment that has been proven effective.
The PPSS is capable of processing a wide range of parcel sizes from small mailing packets to medium cartons up to 22 lbs./10Kg in weight.
The front of DHL eCommerce’s new automated parcel sorting system includes a three to four-person manual induction feeding area. It is designed to allow DHL the ability to use one to four operators to feed compatible packets and parcels at speeds up to 3,000 pieces per hour assuming optimal size and weights, depending on length of the items.
As with most versions of the PPSS, the system is flexible and modular. This makes it easier to change out components to increase throughput as needs evolve. The PPSS is designed with specific zones for the different processing steps required for international cross-border shipping.
The PPSS system has all the components necessary to feed, barcode read, weigh, dimension, label and sort packets and parcels within the specified size and weight ranges and machinable characteristics.
The process begins with feeding packages to the Induction conveyor. After gapping packages, the data is captured via ID Parcel and Mail Solution’s DWS system in zone one. Using MK North America’s high-quality conveyors, designed and built to ID’s specification, packages move through the various processing zones.
Automated dimensioning, weighing, and scanning are accomplished with quality, proven technology. Two Datalogic AV-900 high speed barcode reading systems with integrated LED lighting are included for 1D/2D barcodes covering a range in height from 1/4” to 18” (6.35mm to 457.2mm). This includes one in Zone 1 for the DWS process and one in Zone 3 for the sorting process.
The system features a Wipotec Precision in-line weighing scale that can handle up to 22 lbs./10Kg weight capture. The Datalogic DM3610 dimensioning system captures dim length, width, and height dimensioning at +/-0.2” (5mm) accuracy for cuboidal packages. Both are Legal for Trade certified.
To better help the continual flow of parcels and avoid backups, zone 2 of the system includes ID Parcel & Mail Solutions’ proprietary parcel labeling over-under conveyor design to provide an accumulation queue and takeaway conveyor and 10 Manual Labeling Stations for fast labeling and reintroduction. The accumulation queue allows parcels to be presented to multiple labeling stations and if necessary, held on the conveyor while waiting for their turn so the system doesn’t have to stop upstream. The takeaway conveyor design is a space-saving way to move parcels away after they’ve been labeled. One conveyor level brings parcels in to the Labeling Zone and another to carry them out to the Sorting zone.
The final processing zone on the PPSS is ID’s integration of the highly reliable Fortna MHS NBS90 sorting conveyor with 23 bidirectional modular diverting systems for sorting directly into 46 gaylords and/or chutes with rolling hampers with smart tracking sensors to ensure packages arrive at sorting outputs. ID Parcel’s and Mail Solutions’ Package to Container Nesting package with sorting outlet control panels, chute sensors, and container label printers are included for high volume outlets. This provides tracking packages to the 16 Gaylord containers and printing of DHL container labels as containers are closed.
The solution included ID Parcel & Mail Solutions’ development and customization of software to integrate DHL-provided API interfaces with the DHL IT system, as well as commissioning, acceptance testing, and training for DHL staff responsible for operating the system.
ID Parcel & Mail Solutions is proud to have designed, built, delivered and installed this system for one of the world’s leading logistics companies. It will deliver up to 4 – 5 times throughput per man hour compared to current manual processing. And it does so with a relatively low capital investment when factoring in the typically fast return on investment.
