Packet Parcel Sorting System (PPSS)

Packet Parcel Sorting System in U shape configuration
Figure 1- PPSS in a space saving U shape configuration

The innovative, automated Packet Parcel Sorting System handles a wide variety of mail and parcels from small packets up to medium size parcel at speeds up to 4000 pieces per hour. The unique design optimizes processing of packets and parcels by automating key tasks and allowing manual methods for tasks that are best handled by a person at a very affordable system price.

The system can OCR and address label or read a tracking barcode, weigh the item, dimension the item and sends the packet or parcel into a labeling queue, allowing sufficient time for a customer’s MIS to receive data from the PPSS and make a business logic decision for assigning the package to a shipping partner. At the manual labeling stations, operators quickly pull the package from the queue, scan the barcode on the package, and then the required labels for the finalization of the package are printed and applied.

After, the operator places the package on a takeaway conveyor that moves the items to an automated sorting system to finish the process. The sort output can accommodate postal trays, tubs, bags or wheeled carts and uses a very reliable pneumatic diverter roller system for dual sided outputs. Using a narrow belt sorter with pop up bidirectional transfer rollers, the sorting system handles a wide range of packets and parcels.

Product Range of system

The PPSS can handle a wide range of packages from small mailing packets to medium size parcels as outlined in the table below:

Dimensions in Inches/cmLengthWidthHeightWeights in oz/grams/kg
Minimum package size6/154/100.5/1.31.75oz./50g or 3.5oz./100g
Optimal for 4k design throughput15/3812/30.512/30.52kg
Maximum at slower throughput24/6115/3818/4610kg

Packages must have a firm, flat bottom, maintain their overall shape and size, and have a straight edge to justify during induction.  Tubes or packages that don’t maintain their shape likely will fail to successfully process through the PPSS or may process but could be incorrectly dimensioned.  These items should not be inducted but instead should be processed on a manual mail workstation (MMW). Packages that are equal to or smaller than the optimal dimensions stated above can meet the design throughput rate of 4,000 pieces per hour, assuming 100% induction success and label printing rates based on the average queue time.  Large packages will consume more than one induction target thereby reducing system throughput. If heavier weight processing is necessary, a larger version is available that can handle items up to 75 lbs., but processing speed is limited to 3,000 pieces per hour.

The Packet Parcel Sorting System can also be added to enhance processing of mail and parcels from Max-M or the MMW stations by eliminating hand sorting. A robust and industrial design provides outstanding uptime and minimal maintenance. Configurations can be as small as 4 sorting locations to as many as 100 in a single conveyor line. Multiple lines and turns can be accommodated with flexible conveyor configurations.


  • System control and user interface
  • induction stations with gap guidance
  • imaging for BCR and/or OCR processing
  • volumetric dimensioning and weighing modules
  • conveyors, safety and electrical controls
  • USPS, WORLD.ware, INC.ware or custom address recognition software
  • SQL data interface to customer MIS
  • 2 to 8 manual labeling stations and/or print and apply labeling
  • 90 degree turn conveyors for flexible system layouts
  • Sorting system configurable for 4 to 100 outlets

Output container configurable for different container requirements

Optional Powered Roller Conveyors

Power roller conveyors are fully motorized and can be used on their own or in conjunction with belt conveyors. Roller conveyors provide versatility and easy modification for operations processing larger parcels. For operations that process small or mixed parcels, belt conveyors are required because smaller pieces can get caught in, or fall through, the space between each roller.


  • The modular nature of roller conveyors makes them easily modifiable. This type of conveyor is an excellent choice for operations that are growing or anticipate changing system needs down the line.
  • Allows for better control of parcel singulation in environments of high throughput.
  • Rollers allow for zero line pressure accumulation as parcels accumulate at the end of the line. This is beneficial for operations that have mixed weight, fragile, and/or small parcels.
  • Low maintenance and cost effective.

Belt rollers have several advantages and applications. Systems with inclines require belts because rollers will not grip the parcel when moving on an incline. Belts will allow you to track loads that are close to sortation, as they allow more control over the parcel. And belts are critical when scanners and diverters are being used as they hold the package in a specific position.


PPSS with 2 labeling stations and manual sorting
Figure 2- PPSS with 2 labeling stations and manual sorting
PPSS in a straight-line configuration with 14 sorting outlets
Figure 3- PPSS in a straight-line configuration with 14 sorting outlets
PPSS with 24 sorting outlets and optional pass-through processing
Figure 4- PPSS with 24 sorting outlets and optional pass-through processing