Dual Split Tray (Bomb Bay) Sorter: High-Speed Apparel Sortation

Technology Overview

The Dual Split Tray Sorter, commonly known as a Bomb Bay Sorter, is a high-speed vertical discharge sorting solution, prominently deployed in the fast-paced environment of apparel distribution. This specific implementation by EuroSort features a dual-level design, effectively stacking two independent sorters vertically to maximize throughput within a given facility footprint. The system is engineered for the final stage of order fulfillment, where individual items are sorted directly into the outbound shipping cartons that will be sent to stores or end customers. With a remarkable speed of up to 14,400 items per hour per sorter level, this technology addresses the critical need for rapid and accurate sortation in large-scale fashion and apparel distribution centers, directly linking the sorting process to the shipping dock.

How It Works

Core Principles

The system operates on the "bomb bay" or split tray principle. Items are carried in trays that move along a conveyor loop. When a tray reaches its assigned destination, the bottom of the tray splits open or retracts, allowing the item to drop vertically by gravity into a waiting carton or tote below. The dual-level design means there are two separate conveyor loops (one above the other), each with its own set of trays, effectively doubling the sortation lanes in the same floor space.

Key Features & Capabilities

Dual-Level, High-Speed Design: The system's standout feature is its dual-level configuration, which effectively doubles the sorting capacity compared to a single-level sorter occupying a similar footprint. Each level is capable of sorting up to 14,400 items per hour, yielding a total potential system throughput of 28,800 items per hour.

Direct-to-Carton Sortation: Unlike sorters that discharge to chutes requiring a subsequent packing step, this system sorts items directly into the outbound shipping carton. This "sort-to-pack" methodology eliminates a handling step, reduces labor, and minimizes the risk of mis-sorts during repacking.

Integrated Material Flow: The system includes a conveyor to automatically move filled cartons from the sortation stations to the shipping area. This creates a seamless, continuous flow from order sortation to outbound loading, improving operational efficiency and reducing manual carton handling.

Advantages & Benefits

The primary benefit is the extremely high sorting throughput achieved through dual-level operation, enabling the processing of massive daily order volumes typical in large apparel distribution. The direct sortation into shipping cartons provides significant labor savings and acceleration of the order cycle by combining sorting and packing into one step. The compact dual-level footprint is a major space-saving advantage, allowing high capacity to be installed in facilities where floor space is limited or expensive. The integrated conveyor to shipping streamlines the downstream process, reducing manual transport and improving workflow continuity.

Implementation Considerations

The system requires a manual induction process, which must be staffed and managed to keep pace with the sorter's high speed to avoid becoming a bottleneck. The facility must have adequate vertical clearance to accommodate the dual-level structure, including space for maintenance access. The bomb bay drop mechanism necessitates that sorted items be able to withstand a controlled fall into a carton without damage; very delicate or easily tangled items may require evaluation. The layout of destination stations and carton staging must be carefully planned for optimal operator ergonomics and flow.

Use Cases & Applications

Ideal For

This technology is ideal for large apparel wholesalers, fashion retailers with massive distribution centers, and third-party logistics providers specializing in garment fulfillment that require ultra-high-speed, accurate sortation of individual items into outbound orders.

Performance Metrics

The source provides a clear and critical performance metric: throughput of up to 14,400 items per hour per sorter. With two sorters (top and bottom level), the total system capacity is effectively doubled. The direct sortation to carton is a key efficiency metric, reducing the traditional "sorts per touch" ratio and improving overall lines per hour per laborer. The inclusion of the shipping conveyor directly contributes to reducing the order-to-ship cycle time.

Conclusion

The EuroSort Dual Split Tray (Bomb Bay) Sorter represents a high-performance, space-efficient solution tailored for the demanding throughput requirements of modern apparel distribution. Its dual-level design is a smart response to the challenge of maximizing capacity within existing buildings. By integrating the sorting and packing steps and automating the movement of completed orders to shipping, it creates a highly streamlined and efficient outbound process. For large apparel distributors facing peak seasons and growing order volumes, this technology offers a path to significantly increased throughput, reduced labor costs per sorted item, and a faster, more reliable order fulfillment pipeline.