Dual Split Tray Sorter: Over-Under Apparel Store Replenishment

Technology Overview

The EuroSort patented Dual Split Tray Sorter, configured in an innovative over-under design, is engineered for the high-stakes environment of apparel store replenishment. This application demands sorting massive volumes of individual garments or packaged apparel into precise store orders at exceptional speed. The system's over-under configuration stacks two independent sorting levels vertically, dramatically increasing throughput per square foot of facility space. Capable of processing up to 28,000 items per hour when fed by two induction lines, this sorter is built for speed and efficiency. Its operation culminates in sorting items directly into the outbound shipping carton, streamlining the process from sortation to shipment in a single step, which is critical for meeting tight retail delivery windows.

How It Works

Core Principles

The system operates on the bomb bay sorting principle with a dual-level, over-under layout. Items are placed onto trays on either the upper or lower conveyor level. Each tray, upon reaching its assigned destination, opens at the bottom, allowing the item to drop vertically directly into a waiting shipping carton positioned below. The "over-under" design refers to the two separate sorting loops operating one above the other.

Key Features & Capabilities

Patented Over-Under Design: This space-saving configuration places two complete sorters in a vertical stack, effectively doubling the sorting capacity within the same floor footprint as a single-level system. This is the key to achieving ultra-high throughput in space-constrained facilities.

Very High Throughput with Dual Induction: The system is rated for up to 28,000 items per hour, supported by two dedicated induction lines. This dual-feed design is essential to keep both the upper and lower sorter levels operating at full capacity.

Direct-to-Carton Sortation: A signature efficiency feature, the system sorts items directly into the final outbound shipping carton. This "sort-to-pack" methodology eliminates an entire handling step (transfer from sorter chute to carton), saving significant labor and time.

Advantages & Benefits

The primary benefit is the ability to achieve exceptionally high sorting speeds for store replenishment, enabling distribution centers to process more orders in less time, which is vital for frequent retail delivery cycles. The over-under design provides unparalleled space efficiency, allowing existing facilities to dramatically increase their sortation capacity without expanding their building footprint. Direct sortation into cartons delivers major labor and time savings by combining two processes into one, accelerating the order-to-ship cycle. The system's high throughput, when coupled with efficient induction, offers a strong return on investment for high-volume apparel distributors.

Implementation Considerations

Sustaining the high throughput is dependent on the manual batch induction process. The induction stations must be ergonomically designed and staffed adequately to feed both sorter levels continuously at a rate close to 28,000 items per hour. The over-under design requires significant vertical clearance in the facility for installation, maintenance access, and the drop height into cartons. Items must be suitable for a vertical drop into a carton without damage or tangling. The layout must efficiently support the staging and swapping of hundreds of outbound cartons beneath the sorter.

Use Cases & Applications

Ideal For

This technology is ideal for large national apparel retailers, wholesale distributors, and high-volume fashion brands that operate their own distribution centers and need to sort thousands of store orders daily with maximum speed and efficiency.

Performance Metrics

The key performance metric is a system throughput of up to 28,000 items per hour, enabled by the dual-level design and dual induction lines. The over-under design is itself a key metric for spatial efficiency, effectively providing double the sorting lanes. The direct-to-carton capability significantly reduces the "touches per item" metric, directly translating to lower labor cost per sorted piece.

Conclusion

The EuroSort Over-Under Dual Split Tray Sorter represents the high end of performance for apparel store replenishment sortation. Its patented vertical design is a masterstroke in maximizing throughput per square foot, a critical consideration in logistics real estate. For apparel distributors facing relentless pressure to turn around store orders quickly and accurately, this system offers a formidable solution. By combining extreme speed, space efficiency, and a streamlined direct-to-carton process, it addresses the core operational challenges of volume, space, and labor. Successfully implementing this system hinges on mastering the upstream induction process to unleash its full potential, making it a transformative investment for distributors ready to operate at the highest level of efficiency.