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  • Why the Best Material Handling Solutions Begin with the Right Questions

    Why the Best Material Handling Solutions Begin with the Right Questions

    The on-demand expectations of customers are increasing every day, and fulfillment warehouse operators feel this pressure more than anyone. So, when it’s time to update your systems, it can be tempting to “just get a quote” and move your project forward. But good material handling design requires time and careful planning. There really are no “instant solutions.”

    To implement the most impactful fulfillment automation technology for your operation, a vendor first needs to establish a basic understanding of your business, and a detailed understanding of how orders flow through your warehouse, in a step-by-step fashion. It necessitates asking the right questions and uncovering hidden challenges. Vendors who skip these steps and jump straight to pricing often leave critical details unaddressed, leading to unnecessary change orders, unexpected expenses, and operational headaches – and often can experience huge financial losses to their business as a result.

    At StreamTech, we opt for a more thoughtful intake approach that sets everyone up for smoother implementation and better long-term success.

    The Value of Thorough Application Engineering Before the Proposal

    In the same way highways and freeways are meticulously designed to get us from point A to point B, road development plans are not approved before and extremely thorough assessment process. The same is true for fulfillment automation: The path from raw goods to the end customer depends on a system designed to move items efficiently, but building that system requires careful consideration.

    Material handling is inherently complex. It involves many variables, from the size and weight of packages to the layout of the facility, the volume of orders, the data exchange within the software stack, among others. By taking the time to collect comprehensive data upfront, automation technology vendors can design systems that align perfectly with your operation’s needs. This ensures not only a smoother implementation process but also better long-term outcomes. Vendors who don’t ask the right questions upfront and jump straight to pricing often wind up with unnecessary change orders and expenses, leaving customers to deal with the fallout.

    Questions Every Warehouse Automation Systems Vendor Should Be Asking

    When evaluating warehouse automation systems and comparing proposals from different vendors, it’s important to know that you’re comparing apples to apples. At first glance, one proposal might appear less expensive than another…but a closer look often reveals gaps in the information collected by the vendor. If the vendor hasn’t taken the time to understand your operation in detail, their proposal may be missing key components. While this might make their pricing look attractive upfront, those gaps will likely lead to expensive change orders later when unforeseen needs arise during the implementation process.

    Some of the items that vendors may not include in their proposal may shock you: installation, commissioning, on-site training, even controls and software, support and warranty, to name a few.

    The vendors asking the right questions aren’t just providing accurate pricing; they’re laying the groundwork for a solution that will perform reliably and efficiently from day one. Here are some of the essential questions every vendor should be asking to design a system that works for your unique operation:

    • What are your smallest and largest box sizes?
    • Do you handle boxes, bags, flats, padded mailers, or a combination?
    • What is your average daily volume, and how does that fluctuate during peak seasons?
    • How long is your workday, and does your operation run in shifts?
    • What’s the difference between a typical day and a peak-volume day?
    • How many pack stations are currently in use?
    • Where are your LPN barcodes located—left, right, top, bottom, or multiple sides?
    • Are any items unusually long, heavy, or difficult to handle?
    • Are flat items being handled, and do photoeyes need to be positioned differently to detect them?
    • What type of WCS (warehouse control system) connection will be required?
    • How long does it take to pick an order, and how many people are involved?
    • How many lines are typically in each order?
    • How many SKUs are in your inventory, and what percentage are high movers?

    These final few questions are just as vital to system design. Knowing your pick rates helps right-size equipment and avoid bottlenecks or overspending. Your average lines per order determines the complexity of picking logic and cartonization. Understanding your SKU mix and fast movers ensures the system can prioritize efficiency, especially during peak demand. And your WCS requirements impact everything from scan logic to labeling to system visibility—miss this step and even the best equipment won’t deliver. 

    The Cost of Cutting Corners in Application Engineering Prep Work

    Rushing through the initial design process or missing critical details can lead to major consequences, both operational and financial. Some examples:

    Oddballs and Outliers. Let’s start with the matter of outlier items. A system designed to handle 90% of your orders efficiently may struggle with the remaining 10% if those items are unusually large, heavy, or oddly shaped. Addressing these exceptions requires a thoughtful approach—one that balances the need for efficiency with the flexibility to manage unique challenges. Skipping this step can lead to a system that’s either overengineered and inefficient or underprepared and prone to failure.

    Barcode Placement. Barcode placement is another common area where oversights occur. Imagine receiving a system designed to read barcodes on one side of a box, only to find out during installation that your boxes have barcodes on multiple sides. Suddenly, you’re faced with the need for additional scanners and the associated expenses. These types of surprises can disrupt timelines, inflate budgets, and create headaches for all stakeholders.

    Good Material Handling Practices. Even seemingly minor details, like the gapping of items on a conveyor, can become significant challenges. When items are placed too close together, it can interfere with essential processes like weighing, dimensioning, or labeling. To address this, systems must include conveyors that create gaps between items, a step that requires careful planning and precise engineering. Without this consideration, the entire system’s efficiency can be compromised, leading to delays and reduced throughput.

    Product Packaging Profile. Finally, product packaging can also present challenges that are easy to overlook. Bagged items, for example, can be difficult to convey, label, or sort due to their irregular shapes. Whether it’s a basketball in a polybag rolling unpredictably or a pill bottle shifting within its packaging, these issues must be addressed during the design phase. Failure to do so can result in jams, labeling errors, or damaged products.

    Real Results: When SteamTech’s Process Pays Off

    At SteamTech, the upfront work we do is what sets our solutions apart. By taking the time to ask the right questions and understand the intricacies of your operation before finalizing your proposal, we can better ensure that your system is designed to meet your needs today and adapt to your challenges tomorrow, all while staying within budget and on schedule. After all, the success of any material handling system depends on the foundation laid during the design phase. Take these StreamTech client success stories for example:

    • World Wide Technology: To improve their outbound shipping process for high-value electronics, we delivered a SLAM system that accommodates a wide range of package sizes and labels while reducing errors.
    • DCL Logistics: For this 3PL, we created an adaptive system capable of scaling during peak demand periods, enhancing their ability to support high-growth eCommerce brands.

    How We Turn Discovery Into a Deliverable You Can Trust

    When it’s time to start the conversation, remember we aren’t just pricing machines. We’re designing processes tailored to your business. This takes time. Depending on complexity, our sales and application engineering process may take weeks or months and involves:

    1. Initial calls or virtual meetings to gather information.
    2. Requests for photos, videos, and layout drawings.
    3. Iterative virtual meetings to refine the concept.
    4. Site visits to finalize details.
    5. Delivery of a fully engineered proposal.

    Our thorough process ensures that when your system is installed, it works seamlessly. And if adjustments are needed, we take responsibility for making it right. By contrast, rushing this process can lead to unexpected challenges that may be difficult or costly to resolve later. Taking the time upfront allows us to deliver a solution you can trust, minimizing risk and setting your business up for success.

    Hoping to get it right the first time? Let’s talk.

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  • Is Your Warehouse Ready For Fulfillment Automation? Key Indicators To Watch

    Is Your Warehouse Ready For Fulfillment Automation? Key Indicators To Watch

    Scaling fulfillment volume in a warehouse almost always means having to automate at least some tasks. But automating doesn’t have to be an “all or nothing” proposition. There are often a number of small, easy ways to begin automating fulfillment that provide an ROI faster and allow your operation to scale.

    The first step, of course, is to recognize that your operations are in fact due for a change. The cost and scope of automation systems mean that they should be implemented purposefully, for the right reasons, and in the right places. Here we look at what signals that a warehouse is ready, and offer some practical advice about where to start.

    Busting Some Automation Myths: Is Your Warehouse Ready For Fulfillment Automation

    The hesitancy to automate often stems from assumptions that are outdated or taken out of context. Take, for example, the idea that an increase in automation means a corresponding decrease in jobs. Nowadays, it’s widely accepted that automation can create jobs. It may, however, realign manual and physical tasks to those requiring planning, critical thinking, and problem-solving skills.

    Other myths about automation include:

    Myth 1: “Automation is Too Expensive for Our Business” It’s a common belief that automation requires a significant upfront investment, making it inaccessible for smaller businesses. However, automation doesn’t always mean high costs. With scalable solutions like the Sprinter™ offers a low entry point, taking the burden off pack/ship staff and allowing them to focus on higher-value tasks. The return on investment (ROI) often outweighs the initial costs, especially when automation reduces labor costs, improves efficiency, and eliminates human error. Plus, the Sprinter™ is an affordable entry-level system that sets the bar for fulfillment speed, achieving up to 15 CPM (7,200 parcels) in an 8-hour shift. Many automation solutions, including the Sprinter™, are designed to fit a wide range of budgets, making automation more accessible for businesses of all sizes.

    “Adding the sprinter has allowed us to increase productivity and accuracy while reducing the amount of labor required per package.” – Andrew Mulder, Warehouse Manager, Holland Bulb Farms

    Myth 2: “Automation is Too Complicated to Implement” Some businesses worry that automation is too complex or requires a complete overhaul of their current operations. In reality, automation can be customized to fit a business’s specific needs without the need for a full transformation. At StreamTech, we take the guesswork out of the process with our Applications Engineering service. We scope out each element of your operations, studying your data, analyzing operational challenges, and assessing your package profiles. Our team does the heavy lifting by designing, drawing, and providing a workable solution tailored to your business. You don’t have to worry about understanding the complexities of material handling automation—we do that for you, ensuring you get a seamless and effective automation solution that evolves as your business grows.

    Myth 3: “We Don’t Have the IT Infrastructure for Automation” Many small businesses worry that they lack the IT infrastructure needed to support automation. However, automation today is often designed to be simple to implement, even without advanced IT systems. StreamTech has a team of software engineers who work closely with your IT team to scope out the software interface connection, using standard protocols such as API connections, database or directory sharing, or simply a daily data import. We do the heavy lifting to simplify this complexity, ensuring a smooth integration. While cloud-based solutions and plus-and-play systems make automation more accessible, it’s important to note that your IT team plays a crucial role in this process. We collaborate with them to make the integration as seamless as possible, providing the support needed to implement these tools and ensure they work efficiently within your existing infrastructure.

    Myth 4: “What if the Automation System Breaks Down?” Some businesses fear that automation systems will break down, leading to costly downtime and operational disruptions. While there’s always a risk of technical issues, automation systems are generally reliable, and modern systems are designed with redundancy and backup solutions to minimize downtime. All devices in these systems communicate with our Warehouse Control Software (WCS), which is installed on a PC within the system. The WCS tracks the status of each device and reports this information to the PLC in the control panel. In the event of a fault, our system can alert your operators to the precise location of the problem, enabling quick resolution. Additionally, we can perform remote troubleshooting over the phone to solve issues promptly. To further ensure smooth operations, we also train one of your operators as a “system expert,” so they have a solid understanding of the basics needed to troubleshoot the system. Regular maintenance and a clear support system in place can significantly reduce the chances of major disruptions, and it’s important to note that manual processes also carry risks of error and inefficiency—automation helps reduce those risks over time.

    Signs Your Warehouse Is Ready For Automation

    Once you’re open to the concept of adding automation, the next step is deciding whether or not your operation is ready. Here are seven telltale signs that your manual methods are no longer cutting it and are likely holding your business back.

    1. Your Product Offering Has Grown

    As your product offerings grow, your picking will become more complex. Your pack process will also become more complex for your warehouse staff as they decide which box for each order. Picking automation as well as end of line SLAM shipping automation will aid in this transition, so the operators don’t select the wrong box, and so that the items are picked quickly and accurately as the SKUs grow.

    2. Lack Of Space For Manual Processes

    Often, we receive requests from growing warehouse operations looking to ‘add more pack tables so our team can pack orders faster during peak seasons.’ A savvy material handling applications engineer will take a step further and ask a series of follow-up questions: What tasks are your pack operators performing? If the answer includes handling box selection, taping, entering weights and dimensions, and manually printing shipping labels, there’s an opportunity for automation to take some of these tasks off their plate. Instead of simply adding more pack stations, we might suggest automating the packing process itself—such as performing the picking directly into the carton, adding in-line taping, gathering dimensions and weights, and applying the shipping label all along the conveyor in real time. By automating these tasks, we might even be able to reduce the number of pack stations needed, saving valuable space while increasing efficiency.

    3. Errors Are Affecting Your Bottom Line

    Even small mistakes in picking, packing, or labeling can add up and affect customer satisfaction and your bottom line. Automation significantly reduces human error, ensuring higher accuracy and fewer costly mistakes in your operations. Mistakes cost money and make customers unhappy. One of the biggest advantages of any automation is that it removes human error. Mis-keying an address, picking the wrong item, or choosing the wrong box size is greatly reduced.

    4. Too Many Human Touches Per Order

    When orders require multiple manual steps-sorting, labeling, packing, etc. – it can lead to inefficiencies and delays. Manual processes and operational bottlenecks increase the chances that the team won’t meet their daily or weekly fulfillment goals. Automation helps reduce the number of manual touches per order, speeding up fulfillment and ensuring that your team meets daily and weekly goals more effectively.

    5. Carrier Chargebacks

    Incorrect package weights, dimensions, or labeling can result in costly chargebacks from carriers. By automating the measuring and labeling process, you can ensure that packages are correctly weighed and dimensioned, helping you avoid extra fees and reducing shipping costs—and can rate shop for the best price too.

    6. Running at Maximum Capacity

    If your warehouse is operating at or near full capacity, it may be not easy to accommodate more orders or clients. Automation can help you optimize processes and increase efficiency, giving you the flexibility to grow and take on more business without sacrificing performance. How well would your warehouse be able to accommodate a new client? If signing on a new account is a source of anxiety rather than celebration, it’s time to look at automating. Every business needs room to grow, and if you’re already running at nearly 100%, the best option is to optimize efficiency by saying goodbye to manual operations that aren’t absolutely necessary.

    Simple Automation Solutions For Big Results

    Automation doesn’t have to be intimidating or overwhelming. In many cases, simple automated solutions can provide significant benefits:

    • Maximizing Efficiency with End-of-Line Shipping Automation: Packaging automation that either builds a unique box sized for each order or merely forms and seals them automatically can be a huge step in the right direction. Paired with StreamTech’s conveyor, weigh, dimension, labeling, and sortation systems, this type of solution can bring a revolutionary change to the way orders are shipped. This combination not only optimizes packaging but also ensures efficient use of shipping space, reduces unnecessary packaging, and streamlines the entire process. For example, when integrated with the Sprinter, our end-of-line shipping solution, this system calculates dimensions, weight, and applies the correct shipping label at an impressive rate of 15 cartons per minute. For even greater speed, in-motion systems offer enhanced throughput, making it the #1 solution for growing fulfillment companies looking to meet increasing demands with ease.
    • Boosting Accuracy and Efficiency with Pick-to-Light Technology: Pick-too-light technology enhances order fulfillment by guiding workers to the correct items with visual cues, improving speed and accuracy. Whether using StreamTech’s VelocityPick software combine with either Smart Carts or Conveyorized pick modules, or put-to-light solutions, whether you need 10 pick locations or 1000, this adaptable system can be tailored to your specific needs, reducing training time and minimizing errors. With faster, more accurate picking, your team can handle higher volumes and meet growing demand while ensuring top-notch customer satisfaction. Pick-to-light streamlines operations and supports business growth by increasing efficiency at every stage of the process.

    Real-World Examples Of Automation In Action

    Custom Gift Company Implements First Fulfillment Automation, Sees 60% Improvement in Labor Efficiency

    Pic the Gift, specializing in personalized products like blankets and mugs, faced inefficiencies with their manual fulfillment process, especially during peak seasons. Their labor-intensive process required constant role rotation and extensive training, which impacted their ability to meet growing demand.

    Solution: StreamTech’s Automated Fulfillment System

    StreamTech implemented a customized automation solution to streamline Pic the Gift’s process. After printing, blankets are folded, shrink-wrapped with order tickets inside, and tracked through the system. The items are then weighed, dimensioned, and packaged automatically, with quality control checks, label verification, and sorting by carrier—all without manual intervention.

    Results: Increased Efficiency And Reduced Labor Costs

    In just three months, automation handled over 40% of their fulfillment tasks, significantly easing the burden on staff. During their first holiday season with automation, Pic the Gift fulfilled the same number of orders with 60% less labor, eliminating the need for 24-hour shifts and reducing worker fatigue.

    Chris Cormack, Director of Operations, noted, “Automation really showed us what we’re capable of! We were able to get through peak season with the same amount of manpower, less fatigue, and without 24 hour shifts for the first time.“

    Looking Ahead

    As the company grows, Pic the Gift plans to expand automation to improve efficiency further. Ryan Schneider, Process Improvement Engineer, highlighted, “Being able to automate the shipping process has allowed our workers a lot less strain on their bodies. It’s a lot easier for them to do their jobs, which is really important to us. It’s all about making their day to day easy, they’re happy when they come in, when they’re happy, they pay more attention, the job gets done better. We want to continue to provide a safe workplace that allows our people to succeed, and as we continue going that way, the more automation we can get the better.”

    A Mindful Approach To Fulfillment Automation

    There are rare cases where it’s smart to keep the human touch of manual processes in the warehouse. But most of the time, including automated systems will improve efficiency and enable future growth.

    At StreamTech, we believe in a targeted, calculated approach to automation, rather than automating for automation’s sake. We can start by taking a look at your entire throughput process, and then find solutions that make sense for your company and goals.

    Ready for Automation? If you’re looking to improve efficiency and reduce labor costs, contact StreamTech to discuss how we can tailor a solution for your business.

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  • Keys To Developing An Effective Parcel Sortation System

    Keys To Developing An Effective Parcel Sortation System

    Today we are going to be discussing the keys to developing an effective parcel sortation system.

    In today’s fast-paced and rapidly evolving logistics industry, building an efficient parcel sortation system is crucial for streamlining operations and meeting customer demands. With a wide range of package profiles and sizes, finding the right sortation system becomes a critical decision for businesses aiming to optimize their order fulfillment processes.

    Let’s explore the factors that go into selecting the right parcel sortation technology, to design a sortation system that will work for your operational needs. 

    Many Applications For Parcel Sortation Automation

    Before we dive into the specific data points, it’s helpful to recap why sortation automation is helpful in the first place. Warehouse sortation systems are used for many applications, all to improve efficiency, accuracy, and throughput in the order fulfillment process. Here are some common applications for warehouse sortation systems:

    • Order Consolidation: A parcel sortation system is used to consolidate individual items or products from different picking areas or zones into complete customer orders. This ensures that all the required items for an order are brought together in one location before packing and shipping, reducing the time and effort required for order assembly.
    • Order Segregation: Sortation systems can separate different types of orders based on criteria such as destination, shipping method, priority, or customer requirements. This allows for streamlined processing and specialized handling of orders, enabling faster and more accurate fulfillment.
    • Shipping Lane Allocation: Sortation systems can allocate specific print and apply shipping lanes or loading docks to different orders or carriers based on predetermined rules. This helps optimize the flow of goods through the warehouse and ensures that orders are directed to the appropriate outbound areas for efficient truck loading.
    • Routing: A parcel sortation system can route products or items to different areas of the warehouse based on factors like product characteristics, customer location, or specific handling requirements. This ensures that items are directed to the appropriate processing areas or value-added services, reducing unnecessary travel within the facility.
    • Product Sequencing: Sortation systems can arrange products or items in a specific sequence based on factors such as product codes, sizes, expiry dates, or production dates. This sequencing enables efficient picking and packing processes, especially for orders that require specific product combinations or staging for further processing.
    • Returns Processing: Sortation systems can handle returned items by separating them based on the reason for return, product condition, or disposition instructions. This allows for proper inspection, restocking, refurbishment, or disposal of returned goods, ensuring efficient reverse logistics operations.
    • Load Balancing: A parcel sortation system can distribute workloads evenly across different areas or resources within the warehouse, preventing bottlenecks and maximizing resource utilization. This helps maintain a smooth flow of goods through the facility and optimizes productivity.
    • Parcel Error Diversion: Sortation systems incorporate barcode scanning, weight checking, and other technologies to ensure accurate identification and verification of products during the sorting process.  Incorrect parcels are diverted to a jackpot area, or are recirculated to attempt a second run.  The key benefit of diverting errors is that it allows the rest of your fulfillment process to continue running at speed.  Without an error diversion system, the only way to handle an error event is to stop the whole system and manually fix the offending package. 

    Now that we understand some of the ways sortation is applied, let’s look at the factors needed to design a sortation system. 

    Understand Your Package Profiles

    First, we should consider your package profiles. This refers to the characteristics that define your parcel variety such as the size, weight, shape, fragility, and contents of the package. Understanding this will help determine the handling requirements, sorting methods, and equipment needed to process and deliver the package. 

    • Envelopes: Envelopes typically have a flat and lightweight profile, ideal for documents, photo prints, letters, or small items. If envelopes are involved in sortation, it will be important to remember that the conveyance will require between-roller photoeyes that capture the envelope as it travels along the conveyor (envelopes are often thin enough that they go right under traditional side-mounted photoeyes). Also, if envelopes are involved, we can automatically assume the system will require top-mounted barcode scanners, to read ID information on the envelope.
    • Boxes: Boxes come in various sizes, lengths, and weights. Some boxes are RSC’s with flaps, while others may be made by a case erector or other packaging equipment. The amount of variation in box sizes will be a major factor in sortation design. If boxes are all relatively small in size, and items inside are not fragile, they can simply fall into a gaylord off the sorter. If there’s a high variation and the items may be heavy, sortation to either gravity or roller conveyor is best.  
    • Polybags: Polybags are commonly used for packaging clothing, textiles, or soft goods. Polybags can present a sortation challenge, so we have a few technologies we employ that work well. The biggest challenge with polybags is to ensure the barcode is flat, and readable – not crinkled. Secondly, to make sure they sit flat, and have plenty of contact surface with the conveyor and sorter.  A polybag that is thrown on a belt, and lands “standing up” will not work with automation.
    • Pallets/Flats: Sorting palletized shipments will require a wide, high load capacity conveyor, and will require sortation technology that is designed to handle pallets. If the pallets are wrapped in plastic, it will be important to ensure the barcodes are still readable either through the plastic, or ideally placed on the outside of it.
    • Large Items: Some packages have unique profiles due to their size, such as furniture, machinery parts, or large appliances. These items also require specialized conveyor and sortation technology designed to accommodate their dimensions and weight. 
    • Fragile Packages: items that are delicate, sensitive, or prone to damage require careful handling and may require additional protective measures, such as cushioning materials or special packaging designs. If the fragile items make up a very small percentage of your overall daily volume, in some cases it may be best to just keep these separated in a manual handling lane.
    • Hazardous Materials: Items such as chemicals, flammable substances, or biohazardous items have specific regulations and safety requirements that must be followed during handling, sorting, and transportation. They also often require compliance labels to be adhered to the outside.

    Example Video of Large Parcel Fulfillment

    Size & Weight

    It is also important to consider the overall dimensions and weight of your packages. Each sortation technology is designed to accommodate a certain weight, as well as a certain item shape. Small items may not function effectively in certain cases, while long items may also face challenges in other situations.  

    For example, a roller ball sortation system works well for a very wide variety of packages. However, if the items are small and lightweight, and do not have very many contact points on the sorter, they will not divert. As an integrator, we have experience with common challenges and pitfalls like this, and can help steer you toward the right technology.

    Sortation Information

    One of the most important elements to an effective parcel sortation system design is to clearly define the data exchange. There are a variety of data points that can be used to sort packages, and it’s important to know what you are trying to achieve. 

    Sort Codes & Shipping Server Connection

    The most common method we use for sortation would be using a data exchange handshake with our software. Typically when a package conveys into the end-of-line fulfillment system (SLAM), we induct the package and send a data request to the shipping server (WMS, multi-carrier). 

    It contains the LPN of the package, and we request a shipping label as well as a sort code from the shipping server. The shipping server will send us both items, and we apply the label, and store the sort code in our database. This sort code is typically just a text string that the customer provides.  

    Once the package arrives at the sorter, we re-scan the LPN, and query our database for the sort code that we have been provided, and run the sort logic rules that we’ve put in place, accordingly.

    Other Sortation Methods

    • Barcode or Shipping Label Scanning: Packages can be scanned for barcodes or labels containing information about their destination or routing, and then they are sorted according to the software and logic-based rules built into the system.  In some cases this information is contained in the LPN barcode, while in others this information can be contained in the carrier shipping label, which would be read after it’s applied (in this case, we often use the verification scan to double as the sort scan)  This can work for:
      • Zip Code or Postal Code Sorting
      • Sorting by Service Level (express, overnight, etc)
      • Sorting by Carrier (FedEx, UPS, USPS)
      • Customer or Order Information (priority, high value, or VIP clients)
    • Weight-Based Sorting: Packages can be sorted based on their weight, after traveling across the scale. Heavier packages may be directed to different conveyor belts or chutes than lighter ones.
    • Dimension-Based Sorting: Packages can be sorted based on their dimensions (length, width, height). This method is especially useful for handling large or irregularly shaped items. In some cases clients prefer large boxes to go one way, small ones to go another.
    • Routing Information: Packages may contain electronic tags or chips that convey routing information, allowing the sortation system to automatically route them to their designated destination.  This can be effective for final mile routing companies.

    Throughput, Locations & Destination

    The last and most obvious elements that need to be discussed when building an effective parcel sortation system are the speed target, number of locations, and end destination. These go hand-in-hand, and should be considered together. We need to know a daily or hourly throughput goal, so that we can ensure the sorter will operate at the speed required. In some cases, the throughput goal will require a high speed technology, additional diverters, or possibly additional lanes. 

    The final destination and the number of locations matters as well. If your packages are thin, light and not easily damaged, they can be dropped straight off the edge into a gaylord. In other cases, customers may ask us to direct packages to separate lanes to each dock door. Some customers even opt to employ truck loaders, guiding the packages straight into the truck itself.  

    Throughput is important for other reasons. For example, if customers opt to drop their items into 4 separate gaylords, and process about 10,000 packages a day, they might want to re-think it.  There’s a limit to how much a gaylord can hold, and their employees will have to refresh the gaylords many times throughout the day. In this case, it’s best to just include more sort locations to evenly distribute the load (the goal is to reduce manual labor, not just move the labor to another bottleneck in your operation).

    Sortation Technology & Final Design

    At StreamTech, we offer a variety of sorting systems to accommodate different package profiles which include the ModSort®, Urethane Belt Transfer, PolySort, Narrow Belt, and custom options. StreamTech will help you design a system to meet your throughput, package profile, and will configure the controls and software to accomplish your goals.  We will help select the right technology that fits your needs. 

    All of these elements are summarized in our helpful and easily downloadable Parcel Sortation Guide which you can share with your team as well.

    Frequently Asked Questions

    If you have any further questions, please don’t hesitate to contact our customer support team for assistance.

    What is the difference between a fulfillment center and a sortation center?

    A fulfillment center is responsible for storing and shipping products, handling the entire order fulfillment process. On the other hand, a sortation center focuses specifically on sorting packages based on various criteria before they are further directed to their destinations.

    How long is a package sorting?

    The duration of package sorting can vary depending on factors such as the size of the facility, the volume of packages, and the efficiency of the sorting technology. There is no fixed timeframe, as it differs among different logistics operations.

    What comes after the sortation center?

    After sorting, packages are typically directed to their respective destinations. They may be sent to specific shipping lanes, loading docks, or areas designated for further processing and transportation.

    What is a sortation delay?

    A sortation delay refers to a situation where the normal sorting process is interrupted or delayed. This can occur due to various reasons, such as technical issues with sorting equipment, high package volume, or disruptions in the logistics workflow.

    Why is a package called a parcel?

    The term “parcel” is often used interchangeably with “package.” It generally refers to a wrapped or packaged item for shipment. The word “parcel” has historical roots and is commonly used in the context of shipping and logistics.

    What is the difference between a parcel and a shipment?

    A parcel is a single wrapped or packaged item, while a shipment typically refers to a collection of parcels or packages that are sent together as a group. A shipment can consist of multiple parcels bound for the same destination.

    What is the fastest sorting procedure?

    The speed of sorting procedures can vary, and the fastest method depends on the technology and systems employed. High-speed automated sortation systems, such as those utilizing barcode scanning and conveyor systems, are often considered efficient for rapid sorting.

    How do I prepare a parcel to send?

    To prepare a parcel for sending, ensure it is securely packaged and appropriately labeled. Use sturdy packaging materials, affix a shipping label with clear destination details, and adhere to any specific packaging guidelines provided by the chosen shipping service.

    Why is my package still at the sorting center?

    Packages may stay at the sorting center for various reasons, including high volume, technical issues, or adherence to specific sorting schedules. Tracking information may provide updates on the package’s status, and delays are not uncommon during peak shipping times or unforeseen circumstances.

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  • Use Warehouse Automation to Reduce Shipping Errors And Associated Costs

    Use Warehouse Automation to Reduce Shipping Errors And Associated Costs

    Common Shipping Errors: Problems & Solutions

    As consumers continue to increase their online shopping habits, some going so far as to prefer it to retail shopping, it’s becoming more important than ever to have efficient shipping processes in place. Unfortunately, manual shipping processes lead to common shipping errors and increased costs due to human errors. 

    Fortunately,  fulfillment automation offers a wide range of solutions to these challenges, assisting e-commerce businesses that want to streamline their shipping processes.

    In this article, we’ll explore how businesses can use our shipping automation to optimize their processes to reduce shipping errors and associated costs.   

    Rate Shopping by Dimweight

    According to a study of online retailers, 65% said that failed or late deliveries are a significant cost to their business. 

    Problem

    Improperly priced and processed packages can harm a business’s bottom line by increasing expenses and potentially causing delivery delays. Inaccurately assessing the appropriate carrier information (such as weight and dimension)  for a package can result in returned mail or back charges due, resulting in extra fees that accumulate rapidly, especially for large-scale shipping. Under-estimating weight or dimensions costs money in back charges from the carrier, and over-estimating them means you’re paying more than you need to.

    As an example, say a business ships by weight and forgets to consider the dimensions of a package. For the purposes of the example, let’s say they sell custom body pillows. These products don’t weigh much, but they’re also quite long. Despite calculating the weight, carriers now charge by dimweight, dimensional weight, also known as volumetric weight.

    In April 2022, the United States Postal Service introduced the USPS Nonstandard and Dimensional Non-Compliance fees to crack down on merchants who don’t put correct postage and those who ship parcels whose dimensional size affects their ability to ship as many parcels as possible. This change comes well after the 2015 changes UPS and FedEx made to recoup lost revenue.

    If a package’s dimensions are not provided, you will be charged a fee of $1.50. If the dimensions are incorrect, it is a fee of 25 cents. Other carriers implement similar charges. While these charges may seem minimal, they can add up quickly if you ship out multiple orders.

    To demonstrate how quickly these tiny charges can add up, say you ship out 7,000 packages per hour or 150,000 daily. If half of those packages incur carrier back charges and fees of $1.50, the total fee cost alone adds up to $112,500. Therefore, accuracy and dimweight are critically important. 

    Additionally, inadequate postage can lead to delays that can damage a company’s reputation and decrease customer satisfaction. Late or undelivered packages can result in missed opportunities, lost sales, and unsatisfied customers. In fact, according to PwC, in the United States, 17% of consumers will stop purchasing from a brand or company after one bad experience, and 59% will stop after several bad experiences. 

    Solution

    Weight, dimensions, and accurate carrier and recipient information are required for a completely successful shipment. Relying on a person to manually weigh and measure the dimensions of each package will result in human error, which leads to carrier chargebacks. Additionally, some traditional dimensioning systems may not be capable of measuring irregularly shaped packages.  

    If this is your first foray into automating your warehouse or shipping center, considering an all-in-one scan, weigh, dimension, print, and apply shipping system is an easy way to reduce shipping errors due to incorrect postage. 

    These systems are often referred to as SLAM systems (Scan Label Apply Manifest), a term that was initially championed by Amazon during their push toward automating their fulfillment centers.  SLAM systems are highly accurate, using scanners, order ID barcodes, and cameras with verification parity checking at every stage of the process. Orders only ship when the carrier label and LPN (License Plate Number, a unique order ID) information match, ensuring nearly 100% accuracy.  This level of accuracy is actually of paramount importance for the automation to even run successfully.  

    SLAM systems such as StreamTech’s Sprinter™ calculate weight and dimension measurements simultaneously and with nearly 100% accuracy.  Weight is captured along a conveyor scale. For dimensions, there are a few methods. Many dimensioners use LiDAR sensors and 3D imaging technology to capture a package’s length, width, and height.  Others can capture dimensions using a light curtain that can be effective at calculating dimensions for longer packages. After aggregating the dimension and weight data, the system interfaces with your Warehouse Management System (WMS) or multi-carrier system to ensure the measurements correspond with the order, calculate carrier shipping costs based on the measurements, and print the postage label. Not only does this prevent accuracy errors, and help with label compliance, but it also improves efficiency. 

    Order Accuracy Verification

    When a customer receives the wrong item, it is commonly due to an error in the picking stage. This could be due to two similar-looking items or an incorrectly stocked item.

    23% of e-commerce returns are due to customers receiving the wrong item.

    Problem

    When a customer receives an item that differs from what they ordered or an incorrect quantity of items, it is a serious expense for your business. First, there is any possible fallout of the customer’s negative experience; this can be a negative review, the loss of future business, or, worse, both. 

    To protect your reputation, you may let the customer keep the incorrect item free of charge. This means you still need to pay for the replacement stock of the item you accidentally shipped out. This already affects your profit margin on this order. You also have to ensure the customer receives the correct item or number of items. 

    When you send the correct item or additional items to the customer, this incurs more operational costs. The entire pick, pack, and ship process starts over from scratch. This means you have to pay for the labor and materials it takes to ship the item, and chances are you’ll have to spend more on shipping costs to expedite it and keep the customer happy. 

    Not only that, but you also have to pay for restocking any items you incorrectly shipped out to ensure you have proper inventory levels – and double-check the quality of the returned item to avoid repeating the process if a damaged product is shipped to the next customer.  For all of the above reasons, many retailers and 3PLs have opted to skip this process altogether and let customers keep incorrect items.

    Solution

    StreamTech offers a variety of different picking automation solutions to avoid mispicks and improve accuracy, all driven by the StreamTech WCS software. 

    One option to reduce shipping errors due to incorrect products or quantity of products is a pick-to-light system, which aids in manual picking by guiding employees to the proper aisle, SKU, and bin location, and helps them associate the proper items and quantities to the order they belong to. With this type of system, lights, colors, mini displays, and tablets can be used, and each pick is confirmed by the press of a button and can be verified throughout each step by the scan of any number of barcodes (either on the cart, aisle, bin, SKU, or order).

    Other options may include voice-based or robotic-assisted picking, using a hybrid of these options to reduce human walking travel. 

    All of these systems are designed to improve picking accuracy and increase the speed at which your employees pick. 

    As a second quality assurance step, some warehouse operators employ a checkweigher, which can serve the dual purpose of capturing necessary weight data of each order, as well as verifying weight against a predetermined calculation of the order (this works if weights are already well documented for all SKUs in the WMS). During the picking and packing process, a checkweigher integrates with Warehouse Control System (WCS) software; as a package is weighed, the weight is sent to the WCS software to ensure it is within the acceptable range listed for each item in the order. If the package is too light or heavy, the checkweigher will alert you. 

    Using a checkweigher eliminates the risk of human error while increasing order accuracy, which in turn increases customer satisfaction. 

    Packaging Issues

    When a customer receives a damaged product, it can have serious implications on your business. In fact, 20% of e-commerce returns are due to damaged products. 

    Problem

    Improper packaging is one of the leading causes of customers receiving damaged products, which is costly for many businesses. Damaged products result in customer complaints and negative reviews, the potential loss of a repeating customer, as well as the costs to replace the product and ship it back out. 

    There are many reasons inadequate packaging can lead to a customer receiving a damaged product, including:

    • Improper Dunnage (void fill): If the items are improperly protected, the order could arrive damaged. In many cases, adding dunnage is a very manual process with guesswork. Operators visually determine what looks right and tear off some dunnage.  Sometimes operators may overfill and sometimes underfill.  There are ways to automate void detection using sensors that dispense the appropriate amount each time.
    • Poorly Constructed Packaging: Constructing RSCs by hand will result in human errors in sealing or assembling the flaps correctly. A wide range of carton erecting systems are available that will build trays (then lids) or custom-sized RSCs specifically designed for the items inside each order, with consistent results.  
    • Poorly Sealed Boxes: In the event that the flaps are sealed poorly, the box can pop open, and contents can spill out. In some cases, if a box is sealed poorly, the automated shipping label process can “seal” the box temporarily enough just to get through the automation, only for the contents to be lost later.  StreamTech has employed a box closure technology to address this QA/QC issue prior to labeling for this exact reason.
    • Improper Carton Selection: Many WMS software systems have what is called cartonization software built into them, which is the process by which the pickers know which carton is the best one to fit all the items in the order safely, efficiently, and for the best shipping rate. Poor carton selection can result in an excess void or overly dense containers that cannot support the items inside.    

    Solution

    If employees are manually packaging products, it will inevitably introduce human error into the process. Additionally, if you already rely on fulfillment automation, the integrity of the box is vital to the success of your automated processes. 

    A variety of solutions can be employed to reduce shipping errors caused by packaging issues. In the case of a manually-constructed RSC, there are semi-automatic tapers and box erecting systems that can hold down and seal the bottom flaps while orders are packed and then allow the operator to push the box through to seal the top flaps. If the volume is higher and the ROI is justifiable, a wide range of on-demand carton erecting systems can be added to ensure a consistent, right-sized carton every time.  

    In fact, a carton erector can be a fantastic addition to end-of-line automation, as it provides a high level of assurance for the package’s integrity. For example, if you’re using a SLAM system, the box needs to be properly closed. Otherwise, it can lead to issues with the print-apply and dimensioning systems. In other words, the shipping label won’t properly adhere to the package, or the dimensional measurements will be incorrect. A package unable to be delivered for a missing label or incorrect dimensions results in hefty chargebacks from your carrier and a dissatisfied customer. 

    Additionally, a package that isn’t properly sealed can even result in damage to your labeling system, which is expensive to repair. It can also result in damage to the customer’s product inside.

    In the case of poorly closed or assembled boxes, StreamTech can provide a package inspection system that acts as a QA/QC to ensure the box is constructed properly. This system can be incorporated directly after a box erector or a manual pack station, just before inducting packages into our Sprinter™ SLAM shipping system, which then dimensions, weighs, prints and applies shipping labels, verifies the process, and then can control sortation.   

    Wrong Address

    Incorrect or incomplete addresses cause 74% of failed deliveries.

    Problem

    Incorrect shipping addresses can impact businesses, increasing costs and customer dissatisfaction. When products are shipped to the wrong address, a business may incur additional shipping fees and labor costs to reship the product to the correct address or deal with the fallout of the customer not receiving their order. These costs can quickly add up and impact the bottom line. Moreover, incorrect shipping addresses can delay delivery, leading to negative customer reviews and harming the business’ reputation. 

    Solution

    Automating your shipping using StreamTech’s Sprinter™ Shipping Station is a simple way to reduce shipping errors due to wrong addresses because it has a deep connection to your order database and it has verification built-in. 

    The Sprinter relies on a tight connection to your TMS (Transportation Management System) software, or multi-carrier software. This connection allows us to gather the data of the package, transmit that data, and receive the shipping label associated with that order. The system scans the LPN or identification barcode at the beginning of the process, records dimensions and weights, and then applies the shipping label it receives from your TMS. After applying that label, there is a verification scan that takes place, along with a parity check.

    During the parity check, the WCS ensures that the shipping label is correct and that it matches the order associated with the LPN that it’s supposed to.  

    By leveraging our Sprinter™ Shipping Station, businesses can improve shipping accuracy and efficiency while minimizing the impact incorrect addresses have on their bottom line. 

    Conclusion

    Implementing fulfillment automation is a simple and effective way to reduce shipping errors and their costly consequences. 

    If you’re ready for automation, contact us today.

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  • What Is A Material Handling Systems Integrator, And Why Should I Use One?

    What Is A Material Handling Systems Integrator, And Why Should I Use One?

    What:

    • Connects a variety of different technologies together, from different manufacturers
    • Integrates the technologies to work cohesively, intelligently, and safely

    Why:

    • No equipment manufacturer can provide everything you need – they specialize
    • Integrators have a broad, unbiased expertise across a wide range of technologies
    • We’ve written software that makes your system smarter
    • You don’t have to do it alone – we’ve seen some things and can offer helpful advice and ideas to make your automation smarter
    • Keep pace with changing technology and growing customer demands

    Fulfillment Automation Integrators Are Material Handling Technology Experts

    Are you looking at updating your distribution warehouse to improve material flow and increase productivity? If so, there is a wide range of technologies to explore, and once you begin to get an understanding of the types of systems you have a need for, you should then reach out to a systems integrator to help.

    Why? Designing a successful material handling system requires the integration of a wide range of specialized technologies, from a number of different manufacturers. Scales, dimensioners, scanners, conveyors, control panels, photo-eyes, printer applicators, diverters, lights, alarms, sensors, robots, vertical lift modules, case erectors, baggers, tapers, palletizers, document inserters, and software – all these technologies have to work together in concert to create a successful fulfillment automation integrator system.

    Each of these technologies is developed by companies that are highly specialized in each of their own areas of expertise, to develop the best products in their category. There is no manufacturer who makes every device necessary for your warehouse, and none that will connect them all.

    A Material Handling Systems Integrator Is Able To Provide Unbiased Advice On What Technologies Are Best Suited For Your Business’s Challenges, Goals, And Product Details

    The role of a material handling systems integrator is to manage the design, equipment, and installation of a cohesive material handling automation system. A systems integrator consults with clients to understand their facilities and business needs and designs a system with a wide variety of interconnected, specialized technologies that meet those needs.

    The systems integrator will design and implement a customized solution based on your specific requirements, to meet your goals. They’ll recommend trustworthy brands and equipment that works well with others, and will efficiently process the types of items your warehouse handles.

    You’ll Need Warehouse Control System (WCS) Software To Interface With The Hardware, And The Best Integrators Have Developed Their Own

    An effective material handling system requires communication on both a hardware and software level as well. Today’s warehouses run on a software to manage things like inventory, orders, transportation, receiving, replenishment, manifesting, sortation, and more. Understanding how the equipment will send and receive data between all of these software tools is critical.

    The best fulfillment automation integrators have developed their own in-house software to manage these connections between hardware and software. This is called the Warehouse Control System (WCS) software. It should be able to handle the hardware handshakes between equipment such as conveyors, scanners, scales, printers, and control panels, and should also be able to communicate with the ERP, WMS, multi-carrier, and other software platforms.

    A computer showing data for an automated healthcare fulfillment system

    A Warehouse Control System (WCS) is a real-time, integrated control solution that manages the flow of items through the warehouse. They act as a traffic regulator for warehousing activities, with the mission of running material handling systems (and in some instances, the activities of workers). A good WCS system provides a broad, yet consistent interface for material handling systems like conveyors, carousels, palletizers, sorters, etc.

    Key WCS Functions:

    • WCS manages the operations of many types of material-handling equipment
    • WCS exchanges real-time communication of information
    • WCS can synchronize the operation of automated systems, labor, and material
    • WCS unifies the interface and control of automated equipment
    • WCS focuses on one warehouse at a time

    Material Handling Systems Integrators Help Avoid Common Pitfalls And Recommend Best Practices.

    With experience developing material handling solutions for a wide range of industries including eCommerce fulfillment, manufacturing, retail distribution centers, third-party logistics providers (3PLs), and more, a material handling systems integrator will work with you to develop the best solution for your specific business needs.

    The systems integrator plays a key role as the link between different technologies, the warehouse operator’s goals, and material details. Getting any piece of this equation wrong would likely produce a worse result than before.

    Keep Pace With Ongoing Technological Changes With Integrated Warehouse Systems

    Technology changes, business requirements change, and the expectations of the warehouse will change over time, and integrators help companies keep their systems relevant. Integrators also help companies make better use of their space by identifying opportunities for automation, or performance-based solutions as they become available. Integrators are often involved with implementing new warehouse management software and technologies that can be used to reduce costs while improving service levels to customers.

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  • Why Is Automated Scanning So Important When Designing Fulfillment?

    Why Is Automated Scanning So Important When Designing Fulfillment?

    Introduction To Package Identification

    For any successful fulfillment automation system to operate properly, the equipment must be able to uniquely identify each package. This identifier may be a License Plate (LPN) (for a pick-pack application — most common in fulfillment), it could be a Tracking Number (receiving applications), a Work Order (manufacturing), or a UPC (bulk shipping). Since a hand scanner is relatively inexpensive but fixed (automated scanning) can be somewhat tricky.

    Barcodes may be 1D, or 2D: 1D codes have a series of variable width lines using symbologies like Code 128, Code 39, or UPC. 2D codes are made up of a checkerboard-like pattern. For example, a QR code is popular for scanning with a smartphone. Other 2D codes include Datamatrix and Maxicode. 2D codes can hold a lot of data so they are great for a weblink or even maintaining explicit information.

    For pick-pack applications, we just need to essentially serialize the orders over a time-slice of perhaps a few days or weeks. Thus 6-9 digits is usually plenty of length and that’s what we’ll focus on for “License Plate” (LPN) applications.

    Implications Of Label Placement

    Understanding the purposes of the LPN and the types of barcodes used, we can dive into the details about why their placement is so important. Once that LPN barcode is read, the automation can begin to assign attributes to the order, such as weight and dimensions. This allows us to print and apply shipping labels accurately and ultimately report on the shipped status, sort location, and other data. We call this the “induct” scan.

    Performing the induct scan requires the placement of a scanner along a side of the conveyor where the LPN will be located – typically to read the LPN on one side of the package. Consistent placement and alignment go a long way toward successful automation, saving you cost on unnecessary scanning equipment. Consistent LPN placement will reduce the number of scanners or cameras necessary to read a label.

    In some cases, it could even allow you to reduce the number of redundant labelers. In a recent project, we were able to eliminate the need for a side-applied carrier label. The customer had requested a top-applied labeler and side-apply as well. However, we got creative – by instructing the operators to place LPNs on the front face of their packages, and induct packages on their side, we could use just one top-apply labeler, and accomplish both goals. A little bit of human cooperation goes a long way. The cost savings can be significant, and is only possible through cooperative owners and operators.

    If the operator is unable to place the LPN in a consistent location, we add scanners to read each side, and each scanner adds to the equipment cost and programming complexity of the project.

    (5-Sided Scan Tunnel on Left; 2-Sided Scan on Right)

    Sure, We Can Do It; But Are You Sure You Want Us to?

    Ultimately, if you are unable to control the placement of your LPN’s, or the orientation of your packages along the conveyor, our engineers can design systems that can read 5 (or even 6) sides of your packages, at any location. These are called scan tunnels, and involve about 10 specialized oscillating mirror scanners, as well as large fixed mirrors to ensure coverage across the entire package. It could theoretically even incorporate a between-roller scanner to capture labels on the bottom. The cost of a barcode scan tunnel over the cost of traditional one-sided or two-sided package scanning technology can be as much as a tenfold factor (or more), so it can be best to consider a compromise to bring consistency to the label placement, where practicable.

    However, there are a variety of high-volume situations where many-sided automated scanning tunnels may be necessary. Situations where you are unable to control the location of the LPN, such as when utilizing only the manufacturer’s UPC label on the outside of the package. Some labeling applications utilize the WMS database and rely solely on the UPC.

    Applications Where Multi-Sided Scanning may be necessary (generally in higher volume, very automated scanning facilities):

    • Cross-Docking: scanning-in product UPCs straight from the dock door, from the manufacturer or supplier, weighing, dimensioning and labeling it straight for outbound carrier shipment, conveying to another outgoing dock, with no product storage.
    • Inbound Receiving: scanning-in product UPCs or carrier labels straight from the carrier’s truck for inventory storage.
    • Package Variation & Odd Shapes: in some instances, products are simply such a wide variety that a scan tunnel can be the most efficient way to account for all the variety. A combination of flats, bags, padded mailers, wide package size variety, and shrink-wrapped products could result in the need for a scan tunnel.

    Often, the best way to meet the efficiency and ROI you are looking for is through some automation, combined with operator consistency as well. StreamTech’s applications engineers will work with you to define the scope of your project and provide recommendations about automated scanning for practical savings opportunities when possible.

    Be sure to learn more about StreamTech

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  • Transition From Manual Sortation to Automated Sortation

    Transition From Manual Sortation to Automated Sortation

    The Problem:

    Not having automated sortation typically leaves you with two options:

    1. Limit shipments to a single carrier (which prevents the need for sortation)
    2. Invest in many people resources to take care of manual sortation.

    Limiting shipments to one carrier will limit your shipping options, and therefore any cost savings associated with rate shopping. However, hiring too many resources to take care of manual sortation costs money and in some cases will wash out the savings from using a multi-carrier. In the end, manual sortation limits your ability to save costs on shipping which makes automation the optimal solution.

    Our Solution:

    At StreamTech, we offer many different automated sortation solutions for different product types, different volumes, and different sortation rules. The product types that we can sort include boxes, padded mailers, irregular objects, and even flat objects. The volumes range from as low as 15 packages per minute up to 120 packages per minute. The number of lanes has no minimum or maximum limit – and the sortation rules are modular. This means a customer can develop as few or as many sort codes as they please.

    Our warehouse control software package allows the customer to program their sort codes into the software and then distribute them to whichever lanes are appropriate. Lanes can have more than one sort code in one lane, but also one sort code can be placed into multiple lanes. Our software will automatically send packages to a second lane if the lane fills up by package count or by a physical sensor. This gives the operator an easy-to-manage time frame to switch out a full bin.

    (Example StreamTech WCS Sortation Screen, Installations)

    Every sorter also comes with a reject lane, also sometimes called a “jackpot” or “hospital” lane. This is necessary so the sorter has a place to send packages that are not ready to ship. This can happen if the wrong label is on the package, if the package does not have a label, or if the barcode scanner simply could not read the label. It is our goal that this reject percentage is less than 1% of total production. These parcels can be manually assessed and sorted, or they can be brought back around and run a second time through the sorter to give the automation another opportunity.

    A new available option that strengthens the accuracy of the sorter is open lid detection. We offer an open package detection system that can flag open packages and either stop them in their place or sort them to the reject lane. Open package detection is important because an open package that properly sorts will lead to a customer not receiving their order. However, your WMS will have it listed as shipped because it successfully sorted, but the package contents will have been dumped out and the carrier will not deliver it. This leads to an unhappy customer, and can be avoided with technology.

    Learn more about StreamTech’s sortation technologies, or get in touch with us today to discuss your project.

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