CSL Unveils High-Speed Packing and Sortation System

A major operational hub

Located in the North West of England, this 350,000+ sq ft facility serves as the main operational headquarters for the customer. As a key hub within their wider network, the site plays a central role in high-volume parcel processing and distribution, and needed a robust, reliable automation solution built for a fast-paced, continuously operating environment.

Built to operate across three shifts, 24 hours a day, seven days a week, the system provides the throughput, capacity and reliability required to keep parcels moving efficiently throughout the operation.

With the capability to process more than 15,000 parcels per hour and sort across 88 destinations, the solution supports a high-volume operation while providing the flexibility to manage multiple carriers, destinations and daily vehicle movements.

The challenge

As parcel volumes and operational demands continued to increase, the customer needed an automation solution capable of supporting a high-throughput, around-the-clock operation — from the 13 packing lanes right through to the carrier sortation system before despatch.

The system needed to:

• Move parcels between the 13 packing lanes with 195 pack stations
• Process high volumes of items including jiffy bags, envelopes and parcels quickly and efficiently
• Deliver rapid throughput and faster parcel processing
• Support a large number of sort destinations
• Operate reliably in a demanding, around-the-clock environment
• Handle parcels for multiple carriers
• Support efficient vehicle loading and despatch
• Deliver improved levels of sortation accuracy
• Provide the capacity to meet current operational demands
• Offer the flexibility and scalability to support future growth

The solution

CSL Automation designed and delivered a bespoke parcel handling and sortation solution tailored to the operational requirements of the site and their clients. The system was engineered to move, identify and sort high volumes of parcels to the correct destination, streamlining the journey from packing through to despatch.

Two vertical Interroll crossbelt sorters provide the capacity required for continuous, high-volume processing. The system sorts parcels across 88 destinations, allowing the operation to manage a wide range of outbound routes and carrier requirements, and integrates with the wider operation to deliver the performance and reliability a 24/7 logistics environment demands.

Delivering performance around the clock

Operating across three shifts and around the clock, the system plays a critical role in supporting the customer and their clients’ online operation. Automation provides the capacity to process significant parcel volumes consistently, helping to reduce bottlenecks and improve the efficiency of the overall material flow.

By combining high-speed parcel handling with accurate sortation across 88 destinations, parcels are processed and directed efficiently towards their onward journey. The solution supports up to 44 carriers and the loading of up to 200 vehicles every day, helping the operation manage complex despatch requirements while maintaining the throughput needed to meet customer demand.

The results

The completed solution gives the customer a high-capacity parcel handling system built for a demanding, continuously operating logistics environment. Key results include:

• Capacity to process over 15,000 parcels per hour, using two Interroll vertical crossbelt sorters
• Efficient sortation across 88 destinations
• Reliable support for a 24/7 operation across three shifts
• Support for over 44 carriers
• Capacity to load more than 200 vehicles per day
• Sortation accuracy of 99.9%
• Daily processing capacity of over 360,000 parcels
• Improved operational efficiency and parcel flow
• Reliance on manual handling reduced by 85%
• Increased capacity to support current and future parcel volumes
• Enhanced visibility and control across the automation system using SCADA protocols