Overview
A sorter conveyor takes a single stream of product and directs each item to the right destination lane. Instead of an operator reading a label and moving a carton by hand, the conveyor identifies the item, usually by barcode scan, and diverts it automatically into the correct spur, chute or packing station.
Sortation is what turns a set of conveyors into a system. It is the point where throughput stops being limited by how fast people can lift and sort, and starts being limited by the line itself. That is why sorters sit at the centre of distribution centres, order fulfilment operations and end-of-line packing, where the same conveyor has to serve many destinations.
There are several ways to make the divert happen, and they suit different products and speeds. Pop-up wheels or rollers rise between the conveyor surface to push items sideways. Narrow belt sorters lift wheels between belts to angle product into a lane. Shoe sorters use sliding shoes that travel across the conveyor and guide the item off gently, which is the most accurate method and handles a wide range of sizes. We select the method from your product mix, throughput and how gently items need to be handled.
Belt types
Pop-up wheel divert
Wheels rise between the conveyor rollers to push product into a side spur. A simple, robust and cost-effective divert for cartons and cases at moderate rates.
Narrow belt sorter
Product runs on multiple narrow belts, with wheels lifting between them to angle items into a lane. Handles small to medium items and multiple divert points well.
Shoe sorter
Sliding shoes travel across slats and guide the item sideways rather than striking it. The most accurate and gentlest method, and it handles a wide range of sizes.
Merge and combine
The reverse operation, bringing several lines together into one controlled stream, which is usually needed upstream of a sorter or before packing.
Key features
Automatic routing
Items are identified by scan and sent to the right lane without an operator reading labels or lifting cartons off the line.
Serves many destinations
One infeed line can feed many spurs, chutes or packing stations, so throughput is no longer limited by manual sorting at each station.
Divert method matched to product
Pop-up, narrow belt and shoe sorters each suit different product sizes, weights and speeds, so the method is chosen for what you actually handle.
Gentle handling options
Shoe sorters guide product sideways rather than striking it, which matters for fragile, printed or retail-ready packaging that must not be scuffed.
Merge as well as divert
Merge sections combine several feeds into one controlled single stream, which is normally required before the sorter can work accurately.
Built to your layout
Number of lanes, divert angles, spur positions and throughput are set from your building, order profile and peak volumes.
Applications
- Order fulfilment and e-commerce dispatch
- Distribution centre routing
- Diverting to packing stations
- Sorting to dispatch lanes and chutes
- Separating product by size, weight or destination
- Rejecting failed or out-of-spec items
- Merging multiple lines into one stream
- End-of-line carton and case handling
Typical specifications
- Divert types
- Pop-up wheel or roller, narrow belt, and shoe sorter
- Divert angle
- Typically 30 to 90 degrees into the spur, depending on divert type and product
- Throughput
- Set by divert method, product size and gap control, and sized against your peak volume
- Product types
- Cartons, cases, parcels, totes and trays with a firm base
- Controls
- Barcode scanning and lane assignment logic, integrated with your existing system
- Layouts
- Straight line sortation with side spurs, plus merge sections upstream
- Frame
- Painted or galvanised steel, or stainless steel for wash-down and damp areas
Typical values for this conveyor type. Final specifications are confirmed for your application on quotation.
Frequently asked questions
What is a sortation conveyor?
A sortation conveyor takes one stream of product and directs each item to the correct destination lane automatically, normally after a barcode scan identifies it. It replaces operators reading labels and lifting cartons off the line, so throughput is set by the equipment rather than by manual handling.
What are the main types of sorter?
The common types are pop-up wheel or roller diverts, narrow belt sorters and shoe sorters. Pop-up diverts are simple and cost-effective for cartons at moderate rates. Narrow belt sorters suit small to medium items across several divert points. Shoe sorters are the most accurate and gentlest, and handle the widest range of product sizes.
Which sorter type should I choose?
It depends on three things: what you handle, how fast, and how gently. A uniform carton mix at moderate rates is well served by pop-up diverts. A varied mix of sizes, fragile packaging or high accuracy requirements points to a shoe sorter. Small to medium items with many divert points suit narrow belt. We size this from your product profile and peak throughput.
How fast can a sorter run?
Throughput depends on the divert method, the size of the items and how consistently gaps between them are controlled. Gap control is often the real limit rather than the sorter itself, which is why the infeed and merge sections upstream matter as much as the sorter when you are designing for a target rate.
Do I need a merge before a sorter?
Usually yes. A sorter works on a single controlled stream with consistent gaps between items. If product arrives from several lines at once, a merge section is needed to combine them into one stream with proper spacing before the sorter can identify and divert each item reliably.
Can a sorter handle fragile or retail-ready packaging?
Yes, with the right divert method. Shoe sorters guide product sideways with a sliding shoe rather than striking it, so printed cartons and retail-ready packs are not scuffed or dented. If presentation matters, that is normally the deciding factor in the sorter choice.