Exacta Put Wall: Modular and Scalable Order Consolidation

Technology Overview

The Exacta Put Wall system, offered by Bastian Solutions, is a technology designed to address the growing demand for efficient and accurate consolidation of diverse goods into individual customer orders. It is a key component in modern fulfillment centers, particularly those serving e-commerce, pharmaceuticals, and electronics, where order profiles are characterized by small size and high product variety. The system combines physical modularity with intelligent software to transform batch-picked items into discrete, ready-to-ship orders. By replacing manual sorting and paper lists with a light-directed, software-optimized process, it streamlines a critical bottleneck in the packing and shipping workflow.

How It Works

Core Principles

The core principle is light-directed order consolidation. The system uses a physical wall with multiple put locations (each representing a customer order) and software-driven light indicators to guide workers in accurately sorting batch-picked items into their respective final orders.

Key Features & Capabilities

The software-driven light guidance is the central feature, creating an error-proof sorting process that is intuitive and fast for operators. The modular and scalable design of the physical wall is a significant capability, allowing facilities to start with a configuration that matches current volume and add modules as order throughput grows. Deep integration with Exacta supply chain software enables intelligent order batching and real-time order tracking, maximizing the system's efficiency gains. The dual-sided light indication seamlessly separates the "put" and "pack" workflows, optimizing labor specialization and throughput.

Advantages & Benefits

The primary benefit is a significant increase in accuracy and efficiency at the critical order consolidation stage, directly reducing mis-ships and labor time. This leads to lower overall fulfillment costs. The system optimizes the entire fulfillment process by enabling efficient batch picking upstream and streamlined sorting downstream. The 100% paperless operation eliminates costs and errors associated with paper lists. Furthermore, the scalable nature of the system protects the investment, allowing the operation to grow without requiring a complete technology overhaul.

Implementation Considerations

Implementing a put wall system is most effective for operations with a high volume of small, multi-SKU orders, typical of e-commerce. It requires a supporting batch picking process to feed it efficiently. Integration with a capable Warehouse Execution System (WES) or WMS, like Exacta, is essential for realizing the software optimization benefits. The physical space must be allocated for the wall structure and the associated workflows (feeding and packing). The modular design should be planned with future growth in mind.

Use Cases & Applications

Ideal For

This system is ideal for fulfillment centers, distribution hubs, and 3PLs that handle a high mix of small items and need to consolidate many individual customer orders quickly and accurately.

Conclusion

The Bastian Solutions Exacta Put Wall represents a highly effective and scalable solution for the order consolidation challenge in modern fulfillment. By combining intelligent software with an intuitive, light-directed physical interface, it dramatically improves accuracy and throughput at a critical point in the workflow. For companies in e-commerce, pharmaceuticals, or similar sectors facing rising order volumes and complexity, implementing a put wall system can be a strategic investment that reduces costs, improves customer satisfaction through accuracy, and provides a flexible platform for future growth.