Short answer: Cross belt and tilt tray sorters are often used in cargo transfer centers and e-commerce fulfillment warehouses to sort shipments by city, route, or vehicle. Sorter directs each package to the correct exit according to the destination information from the cargo software.
Sorter Systems for Cargo are intralogistics automation solutions that enable automatic sorting of parcels, packages and shipments arriving at cargo centers according to criteria such as address, region, branch, route or distribution point. In cargo transfer centers where thousands of shipments are processed per day, manual sorting methods may limit operational capacity after a certain volume. Correctly designed sorter systems help automatically identify shipments and transfer them to the relevant exit points in a controlled manner. Sorter in modern cargo operations; It can work with conveyor systems, barcode readers, sensors, PLC control infrastructure and operation software. After the barcode of the shipment entering the system is read, the target information is checked and the product is directed to the appropriate exit. Thus, Cargo Sorter Systems support the automation of the product flow from the acceptance point to the transfer and shipping area.
Why is Sorter System Used in Cargo Operations?
One of the most important operations of cargo centers is the separation of shipments coming from different points to the correct distribution areas in a short time. Especially during campaign periods, special days and e-commerce peaks, the amount of packages to be processed may increase significantly. Managing this volume with completely manual methods may require more personnel and operational space. Cargo Sorter Systems can help manage high product volumes more regularly by automating repetitive sorting processes.
- Helps reduce the need for manual package sorting.
- Supports high volume shipment flow.
- It makes it easier to route packets to the correct exits.
- It can speed up transfer center operations.
- Increases traceability of shipment movements.
- Supports capacity management during peak periods.
How Does Cargo Sorter System Work?
The cargo sorting process begins with the shipments being taken to the feed line. Packages are transferred to the conveyor at regular intervals and delivered to the identification point. After the code on the shipment is read by the barcode reader, the system determines the route or destination information of the relevant shipment. The control system tracks the position of the product as the package moves on the sorter. When the shipment reaches the destination exit, the sorter mechanism is activated and transfers the package to the relevant line. Cargo Sorter Systems can support the continuity of the transfer operation by automatically performing this process for a large number of consecutive shipments.
Which Sorter Systems Can Be Used in Cargo Centers?
It is not correct to use the same sorter technology in every cargo facility. Appropriate technology should be determined by evaluating daily package volume, peak hour capacity, package dimensions, weight range, number of exits and facility layout.
Cross Belt Sorter
Cross Belt Sorter is one of the sorter technologies that allows shipments to be transferred to designated exits by moving on independent conveyor belts. It can be used in high-volume cargo and distribution operations that require separation into many destinations.
Vertical Cross Belt
Vertical Cross Belt can be used in cargo operations where linear layout is more suitable for the facility structure. It supports automatic transfer of shipments to different exits according to barcode and destination information.
Wheel Sorter
Wheel Sorter can transfer parcels and packages with suitable base structure from the main transport line to different exits through direction-changing wheel mechanisms. It is among the solutions that can be used in operations where continuous conveyor flow is required.
Tilt Tray Sorter
Tilt Tray Sorter is a sorter technology where shipments move on carrier trays and are transferred to the relevant section by tilting the tray at the target exit point. It can be evaluated in cargo operations where there are many separation points.
Roll-On Sorter
Roll-On Sorter is one of the sorter solutions that can be used in sorting projects where product and package features are suitable. For correct system selection, the actual shipment profile and operational capacity must be analyzed together.
Cargo Sorter Integration with Conveyor Systems
In order for the sorter system to operate at high capacity, shipments must be fed into the system in a regular and controlled manner. For this reason, it is important to plan the conveyor infrastructure as a whole in addition to the sorter equipment in Cargo Sorter Systems projects.
Shipments coming from more than one acceptance or feeding line can be transferred to the common sorter line in a controlled manner with merge conveyor solutions. A more balanced product flow can be created when conveyor speed, distance between packages and sorter input capacity are planned correctly.
Automatic Cargo Routing with Barcode Reading
One of the key stages of automatic sorting in cargo operations is the correct identification of the shipment. Sorter Systems for Cargo can work together with barcode readers to automatically detect the shipment code on the package and check the relevant destination information. Read data; A routing command can be sent to the sorter system by matching it with information such as branch, region, route, distribution center or shipping point. In cases where the barcode cannot be read or the destination information of the relevant shipment cannot be found in the system, the package can be transferred to a special control exit. Thus, it becomes possible to control problematic shipments at a separate operation point without interrupting the main sorter flow.
Sorter Integration with WMS and Cargo Software
It is of great importance that physical automation and operation software work together in high-volume cargo centers. Cargo Sorter Systems can help automatically sort products based on shipment information received from WMS, ERP or cargo operation software. After the barcode of the shipment is scanned, the target information defined in the software is transferred to the control system. PLC and sorter control infrastructure follows the physical location of the package and carries out the routing process at the correct exit point. After the process is completed, the new status of the shipment can be transferred back to the software system. Thus, a coordinated process is created between digital shipment information and physical package movements.
Sorter Use in Cargo Transfer Centers
Transfer centers are one of the busiest cargo operation points where shipments from different branches and regions are re-segregated. Incoming packages must be sorted according to target city, region, branch or distribution route in a short time. Sorting operations performed by manual methods can become a significant operational bottleneck as shipment volume increases. Cargo Sorter Systems ensure that packages are taken from common lines at transfer centers and distributed to different exits automatically. It can help process high volume shipments in a controlled manner, especially during busy periods caused by night transfer operations or e-commerce campaigns.
Cargo Shipment and Vehicle Loading Processes
The packages sorted by the sorter must be transferred to the relevant vehicle or loading gate in the next stage. Sorter outlets can be connected directly to shipping conveyors, reducing the need to manually move packages over long distances. This structure helps create a more seamless product flow, from sorting to vehicle loading. Telescopic Conveyors can be used in vehicle loading and unloading operations. In areas with variable vehicle positions or more flexible transportation needs, Accordion Conveyor ( KOALFLEX ) solutions can be evaluated.
How to Determine Capacity in Sorter Systems for Cargo?
It is not enough to determine sorter capacity only by the total number of shipments per day. Since shipments are concentrated at certain time intervals in cargo operations, the maximum amount of packages that can reach the sorter line during peak hours must be calculated separately. When designing Cargo Sorter Systems, the size and weight distributions of the shipments entering the system, the number of feeding points, the target number of exits and the required distance between packages should be evaluated together. Thus, the sorter system can be aimed to meet not only the average operation volume but also the capacity needs that may arise during peak periods.
What Should Be Considered When Choosing Sorter Systems for Cargo?
The shipping profile and operation structure of each cargo center is different. For this reason, when choosing Sorter Systems for Cargo, engineering studies should be carried out based on the real operation data of the facility instead of a standard solution.
- Total daily shipment volume should be analyzed.
- Package capacity during peak hours should be calculated.
- Minimum and maximum package sizes must be determined.
- The weight range of the shipments should be evaluated.
- The required number of sorter exits must be calculated.
- Barcode reading infrastructure should be planned correctly.
- Conveyor and sorter capacity must be compatible with each other.
- PLC and operation software integration should be planned.
- Control exits should be created for unreadable posts.
- Future shipment volume increases should be taken into account.
The Importance of the Correct Sorter System in Cargo Automation
Choosing the right sorter technology for cargo operations can impact the performance of the entire transfer center. Cross Belt Sorter, Vertical Cross Belt Sorter, Wheel Sorter, Tilt Tray Sorter or different sorting technologies can each provide advantages for different product profiles and operational needs. Correctly designed Sorter Systems for Cargo; It supports the automatic management of packages from the acceptance point to the destination exit by working with conveyors, barcode readers, sensors, control software and shipping equipment. Thanks to a scalable sorter infrastructure, cargo companies can more easily adapt to capacity increases that may occur in the future while managing their current shipment volumes.
You can contact us to get detailed information about cargo sorter systems, conveyor automation and intralogistics projects. Contact Via WhatsApp You can review MHI – Material Handling Industry resources for international sectoral information about material handling and intralogistics technologies.
E-commerce fulfillment and order consolidation
In e-commerce warehouses, the sorter does two jobs: it brings together the collected products by order (consolidation) and separates the packed orders by cargo company or route. Capacity should be planned according to the peak day, as the volume increases several times during campaign periods.
- Combining products on an order basis after picking
- Separation of orders coming from the packaging line according to the cargo company
- Sorting of returned products
- Instant retrieval of target information with WMS and cargo software
| Sorter type | Capacity (pieces/hour) | Max. weight | Max. product size |
|---|---|---|---|
| cross belt | 8,000–14,000 | 35kg | 600×400×380mm |
| Tilt tray | 6,000–12,000 | 35kg | 600×400×380mm |
| wheel sorter | 2,500–5,000 | 50kg | 1000×800×800mm |
| narrow belt | 1,800–2,750 | 50kg | 900×600×600mm |
| Roll-on | 1,600–2,400 | 35kg | — |
Frequently asked questions
Which sorter is used in the cargo center?
Cross belt sorters with a capacity of 8,000–14,000 units per hour are common in high-volume cargo centers; Lower volume tilt tray, wheel or narrow belt sorter may be preferred.
Why need sorter in Fulfillment repository?
It is necessary for orders to be combined without errors and separated quickly according to the cargo company; It reduces the error rate and shipping time compared to manual sorting.
Related guides: Cross belt or tilt tray? Comparison of sorter types · 10 questions when choosing a sorter system · KOAL sorter systems
Since 2010 we have designed, built, installed and serviced sorter and conveyor systems in Gebze. These articles draw on our field experience.
