Few things are as synonymous with warehouses in the retail and e-commerce sectors as the sorters and conveyors that move the right products to the right location with speed and accuracy.

Perhaps more than any other warehouse systems, sorters are also among the most time-tested and multi-faceted solutions in use today. There are basic models that still closely resemble their predecessors in use for decades, as well as highly advanced variations that play a crucial role in state-of-the-art facilities.

Regardless of whether an organization is just beginning to consider how to automate its most time-consuming tasks, or looking to refine its operation to achieve new efficiencies, sorting systems should be considered an integral component.

Despite hopes that the difficulty of attracting and retaining staff in material-handling roles was a moment in time caused by the pandemic, most warehouses today continue to struggle with the problem. Today, the shortage of available labor is a nearly universal challenge for facilities of all sizes.

As a result, many smaller warehouses that still rely on predominantly manual processes are considering automation for the first time, with sorting and conveyor systems being the priority. They’re looking to address the 40%-70% of employees’ time spent walking to pick items. Likewise, large distribution centers are examining how their existing sorting systems can be augmented in the face of a labor market that is only expected to grow more constrained. Such improvements are being driven not only by the need to be faster and more accurate, but also to incorporate investments in additional systems that help address the shortage of labor, including robotic picking operations, advanced automated storage and retrieval systems (AS/RS), and autonomous mobile robots.

Just as importantly, they’re looking at how such sorting systems can improve a variety of workflows from the time product arrives at a warehouse until it’s sorted for picking, packaging and shipping to retail stores and consumers. Not surprisingly, given the diverse merchandise sold today, there are numerous options for sorting systems and conveyors available.

Sorting and conveyor systems should be designed to address each materials handling operation’s unique needs. However, there are several basic types that can be categorized by use case. These include the following:

Pocket sorters. Often used for e-commerce picking operations and returns, pocket sorters were first introduced in the fashion and garment industries, but quickly proved their worth in e-commerce operations because they minimize the number of touches involved in the pick process. They are ideal for moderately sized items that are not too heavy.

Shoe sorters. Used for high-throughput applications, these quickly and gently divert moving product down the correct chute for picking or shipping. They are versatile and able to handle a wide range of product packages, containers and boxes and even polybags.

Crossbelt sorters. Part of a conveyor-based sorting system, they are not only able to move and sort a wide array of products and items gently, but are also typically the fastest sorting systems available. But with throughput of 25,000 orders or more per hour, they require more resources to install, configure and maintain.

Bombay sorters. As the name suggests, bombay sorters work by dropping product to the right destination below the sorter. Particularly advantageous for operations that need to make the most of available floor space, they make optimal use of vertical space and enable warehouses to “build up.” Their disadvantage is that they can’t be used for fragile items that are prone to damage when dropped.

Despite the diverse array of choices, there are several considerations that all material-handling operations, from the largest DCs to small warehouses, should consider when vetting various sorting systems. They include the following:

Look at your data. While a sorting system may be the first step toward automation for many organizations, it’s still an important capital investment that should be made with long-term viability and growth in mind. For that reason, it’s imperative to look at what volumes and merchandise will look like five, 10 and 15 years from now, not just what you’re sorting today.

Look at how to use your existing space most effectively. Even the most basic sorting system should also be built with a keen eye on how to use existing warehouse floor and vertical space. In this way, organizations can often increase throughput without increasing its footprint. That’s an important benefit in metropolitan areas, where commercial space is often expensive and limited.

Build with flexibility in mind. Advances in automation continue to radically alter material-handling operations. Whether it’s deploying the latest AS/RS, installing robotic picking operations, or designing lanes for the use of autonomous mobile robots in functions like palletizing, sortation systems should be built with the assumption that additional automation may be desired in the future.

Finally, warehouses of all sizes should request a detailed proposal for the sortation system that not only includes a recommended design and outlines the initial costs, but also what will be required to operate and maintain it. By keeping these factors in mind, today’s warehouses and DCs can benefit from the very best sorting technologies, tools and techniques, today and for years to come.

Andy Lockhart is director of strategic engagement, warehouse solutions, North America with Vanderlande.