Variable product profiles
Products with different dimensions, weights, packaging and code quality must be processed reliably on the same line.
/ INDUSTRIAL SOLUTION
10
Sorter Smart Conveyor Systems
Detect every product, divert it at the right moment and verify that it reaches its destination.
Intelligent sorting lines combine conveyors, detection, PLC, motion control and WCS layers within one synchronised architecture to route high-volume product flows accurately.
Explore the solution
Turn variable product flow into measurable capacity, accurate destinations and verified dispatch outcomes.
Bottlenecks and accumulation
Irregular infeed, full destinations and poor timing reduce capacity and disrupt product spacing.
Risk of incorrect destination
Reading, decision or divert errors can route a product to the wrong order, route or dispatch gate.
/ ONE CONTROL ARCHITECTUREBring mechanical movement and digital decisions
Bring mechanical movement and digital decisions
onto the same timeline.
An intelligent sorter combines conveyors, sensors, code reading, measurement, PLC and WCS layers within one synchronised flow. Position, destination and sorting result are managed simultaneously for every product.
DetectIdentify the product and position
DecideDetermine destination and route
DivertRoute at the correct moment
- Stable infeedProduct spacing and line occupancy are balanced against downstream capacity.
- Deterministic decisionsProduct identity, production order and destination availability are combined in one decision record.
- Closed-loop verificationPost-sort sensor feedback is compared with the destination decision and recorded.
The product moves,
and the decision moves with it.
The graphic shows the real flow from reading the product at the infeed sensor to target assignment by the control system and timed diversion to the correct destination.
CODE + DIMENSIONS01 / DETECT
WCS DECISIONTARGET: EXIT B
PKG
AOTHER ROUTE
BTARGET EXIT
COTHER ROUTE
READDECIDEDIVERTVERIFY
/ ENGINEERING SCOPEMore than speed:
More than speed:
a balanced, verifiable flow.
Capacity depends on more than sorter speed. Infeed geometry, product spacing, read rate, destination occupancy and control latency are engineered together.
Capacity and simulation
Realistic line capacity is modelled from product profiles, peak volume, queue behaviour and destination distribution.
Conveyor and divert selection
Merge, singulation, transport and divert mechanisms are sized according to product behaviour.
Code, dimensions and identity
Barcode, vision, volume, weight and sensor data are matched to the product's digital record.
PLC and motion synchronisation
Encoder position, product tracking and divert timing are managed with deterministic control logic.
WCS and host systems
WMS, MES or ERP destination decisions are combined with line status and exit availability in real time.
Performance visibility
No-reads, rejects, occupancy, cycles and downtime causes are reported for continuous improvement.
A decision is not merely issued;
its outcome is verified.
Sensor feedback is checked after the product is diverted. A no-read, full destination or timing deviation can route the product to a controlled reject or recirculation path.
Product and
position data
Sensors and encoders track the product digitally.
→Destination and
priority selection
The order and destination availability are evaluated together.
→Timed
diversion
The divert mechanism is triggered in synchronisation with product position.
→Exit and
result record
Arrival is detected, the decision verified and the transaction recorded.
From concept to stable production,
in six controlled steps.
- 01Understand product flow
Dimensions, weight, packaging, volume distribution and peak scenarios are mapped.
- 02Model capacity
Infeed, merge, sorter and destinations are validated within one flow model.
- 03Design the architecture
Mechanical, electrical, control, network and host-system integration are developed together.
- 04Test the scenarios
Normal flow, no-read, full destination, reject and safety behaviours are tested.
- 05Commission on site
Timing parameters are tuned with real products and acceptance criteria are verified.
- 06Improve performance
Line data is monitored to reduce bottlenecks, errors and availability losses.
Scalable sorting
for every product profile.
E-commerce and parcel
High-volume sorting of parcels by route, region, distribution centre or dispatch gate.
Warehousing and distribution
Order picking, consolidation, cross-docking and store-based product routing.
Production intralogistics
Routing parts, totes and products by production order, quality result or next operation.
Food and packaging
Controlled sorting by grade, weight, recipe, packaging or quality data.
How we turned a similar need
into an operating solution.
Customer and facility information has been anonymized to meet confidentiality obligations.
Let’s analyse storage and flow
around your real operation.
Share load profiles, throughput targets and space constraints so the right architecture can be assessed.
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