Cross Belt Sorter at an APAC Customer Site

Take a peek to when India's premier logistics solutions provider was struggling with revenue and operational issues. They aimed to achieve speedy, safe & reliable nationwide express delivery services.

Cross belt sorter

The Challenge

The massive increase in demand for durable goods delivery has put strain on logistics and transportation services to keep up with current market demand. The need for an innovative approach to a more pragmatic solution grew as demand from Tier - I cities increased by roughly fourfold. They understood that in such a large market, it's critical to stay ahead of the competition in order to attract customers and acquire a larger share of the continuously expanding pie. The necessity to automate the manual operations thereby emerged as a result of the growing demand.

Our Solution

Cross belt sorter

Polaris - Armstrong Dematic’s Cross Belt Sorter is a one-of-a-kind engineering marvel, that is propelling warehouse automation to new heights. It is one of the highest throughput catering systems, with a speed of 48000/hour and all processing activities are integrated into a single solution. CBS includes parcels inbound movement, induction, weighing, scanning, volumetric, sorting, bagging, outbound movement, data handling. Thus, 'Polaris' includes all significant operations a parcel requires in warehouse processing. The following sections, together with a thorough process flow, elaborate how Polaris addresses each of the challenges mentioned above.

  1. Throughput
    With a throughput of 48000/hour and a run period of 22 hours, the system can process about 2.6 lakh shipments each day, thus solving the challenges of an urban market demand.
  2. The manual sorting issue is readily resolved with 99.4% sorting accuracy. Expertise in automation techniques for conducting each action, as well as adequate communication to reach the desired command, contribute to these high levels of accuracy.
  3. Polaris Software
    The ease of automating data processing using Polaris software & the interface to customer servers enables such large-scale data processing processes.
  4. Quality
    The quality involved in every process of sorting starting from design to execution, ensures that goods are completely safe while being processed in the warehouse.
  5. Automatic
    All of the mentioned primary activities are automated, resulting in improved operator coordination and a reduction in processing time. All of the mentioned primary activities are automated, resulting in improved operator coordination and a reduction in processing time. For instance, movement caused by manual intervention via workers and trolleys occurs through bagging conveyors, simple scanning and parcel placement. Several other automated processes are detailed in the comprehensive process overview. All of the following features are linkedtogether to provide complete operational ease.

Operational Overview

Cross belt sorter

To receive the best results from the sorter, the shipments must first be entered in the layout which Inbound conveyors have provided. As shipments arrive through C-line at the Induct conveyors, four arm diverters assist in diverting the shipments to empty induct chutes based on inputs from sensors installed at the chutes. There are currently 5 induction lines, the fifth of which is known as 'Rejection Induct'.

The CBS loop, which is at the centre of the system, contains 354 carriers that sort supplies at specific destinations. When an operator starts feeding shipments into the loading conveyor, ECDS determines the number of vacant carriers available and loads the shipments onto these carriers, which then travel through the ICR, where the shipments are allocated their destination.

After getting the destinations from ICR shipments travels to specified destinations and get sorted into primary and secondary chutes which is followed by the Put to Light System operators.

We successfully helped India's largest logistics solutions provider soar their earnings and develop a revered market image by increasing efficiency and making sorting operations faster, smarter, and cheaper