Sortation Systems for Warehouse and Distribution Centres
Efficient, accurate material flow is the beating heart of every modern logistics operation, and Sortation Systems play a pivotal role in keeping that heart pumping. At NEPTEK we design, supply, and seamlessly integrate a comprehensive portfolio of sortation technologies that ensure every tote, box, parcel, or flyer bag is routed to the correct destination the first time—no matter how high the hourly throughput or how complex the product mix.
From the moment inbound vehicles dock, product is placed onto telescopic or extendable conveyor booms and introduced to the Sortation System via our heavy-duty inbound conveyor network. Multiple induction lines merge intelligently, balancing the load and preventing bottlenecks. As each item enters the sorter line it is scanned, weighed, dimensioned, and photo-captured in-line, creating a real-time digital fingerprint that follows it all the way to its assigned chute. Integrated PLC and WMS interfaces guarantee that the sorter’s decisions are always synchronised with your inventory data, billing rules, and customer-service targets.
Core Sorter Technologies We Integrate
We supply and integrate the following range of sorter equipment into our sortation systems, depending on the throughput requirement and products to be handled:
- Sorting Robots (AMR) – autonomous mobile robots that dynamically pick up and drop off totes for routing within highly flexible layouts.
- Pop-up Belt Divert – fast 30° or 45° belt modules that raise on demand to deflect lightweight parcels without losing momentum.
- Switch Wheel Sorter – dual-wheel sets that swivel to achieve accurate left-right diversion at medium to high speeds.
- Rotary Pusher Sorter – compact rotary paddles ideal for gentle off-loading of irregular items or polybags.
- Cross-Belt Sorter (Horizontal and Vertical) – high-speed closed-loop carriages offering precise positioning to multiple discharge points while protecting delicate packaging.
- Intralox ARB Sorter – Activated Roller Belt™ technology that provides efficient side-transfer and angle-merge capability with minimal product contact.
- Sliding Shoe Sorter – the industry benchmark for high-volume carton facilities, using aluminum slats and UHMW shoes to achieve quiet, low-maintenance operation.
- Tilt Tray Sorter – gravity-assisted trays that tilt left or right for secure handling of small or fragile merchandise.
- Bombay Sorter – overhead trap-door trays designed for high-speed letter, apparel, and small-item distribution.
These devices can be deployed as stand-alone modules or combined into hybrid Sortation Systems when a single technology cannot economically meet every SKU profile or service-level agreement.
Supporting Technologies Integrated by NEPTEK
Included in our sortation systems NEPTEK integrate the following technology:
- Warehouse Conveyor Systems – modular belt, roller, and zero-pressure accumulation conveyors engineered for 24/7 reliability.
- Inspection Systems (Camera, Scanning, Weighing, and Dimensioning) – best-in-class sensors from Cognex, SICK, Bizerba, Data Logic, and Mettler Toledo provide 100 % traceability and billing accuracy.
- Truck Loading Systems – powered telescopic conveyors, rigid booms, and mechanised chutes that cut turnaround times at outbound docks.
All sub-systems are coordinated through a single intuitive HMI and can be linked to your existing WCS, ERP, or cloud analytics platform for end-to-end visibility.
Advantages of NEPTEK Sortation Systems
- High sorting throughputs possible to cope with peak volumes and future business growth. Our designs routinely exceed 10 000 items per hour while retaining spare capacity for seasonal spikes.
- Traceability of item from induction on the sorter to the destination chute. Every scan event is time-stamped and stored, enabling granular performance reporting and rapid exception handling.
- No mis-sorts resulting in customer claims. Intelligent control algorithms and self-diagnostics detect anomalies before they create costly errors.
- Gentle handling and sorting of items. Carefully selected belt speeds, cushioned diverters, and low-shock chutes protect even delicate e-commerce parcels.
- Eliminate double handling during the sorting process. Automated diversion removes the need for manual resort lanes, freeing labour for higher-value tasks.
- Eliminate inefficiency by not having to have people sort items manually. Labour costs drop, ergonomics improve, and human error is virtually eliminated.
Future-Ready, Service-Backed Performance
Choosing NEPTEK means more than buying hardware; it means partnering with a multidisciplinary engineering team that understands the evolving demands of the courier, express, and logistics market. Whether you are modernising a brown-field warehouse or building a green-field mega-hub, our Sortation Systems scale effortlessly, integrate cleanly with automation already on site, and arrive backed by preventive-maintenance programmes, readily available spares, and remote-support expertise.
Invest in a solution that moves every parcel with confidence, clarity, and speed—invest in NEPTEK Sortation Systems.
