Automated Sortation
Increase throughput, reduce errors, optimise distribution
sortation for warehouses
Sortation and the routing of products is a crucial element for most warehouses and eCommerce fulfilment centres. Whether this is a simple routing change or high-speed sortation prior to despatch, there is a solution to suit all applications.
Utilising various triggers such as carrier labels, barcodes, RFID, LPN (Licence Plate Number), weight, size, colour, etc. running alongside a WMS system, making intelligent decisions to control the hardware.
Boost your throughput
As volumes grow and customer expectations rise, manual sortation processes are under increasing pressure.
Many operations struggle to keep pace without adding cost or complexity.
- Manual sortation bottle necks
- Rising labour costs
- Error rates
- Peak season strain
Our Sortation Range
Low Speed sorters - Up to 3,000 p/h
Low speed sorters provide a reliable and cost-effective way to divert products accurately within conveyor systems, making them ideal for order consolidation, routing to multiple destinations, and controlled throughput environments. CSL Automation designs and integrates low speed sortation solutions tailored to your product range, layout, and operational requirements.
Options Include:
Interroll Belt Transfer • Uni-XU Chain/belt transfer • Itoh Denki F-RAT
Mid-Speed Sorters - Up to 7,000 P/h
Mid-speed sorters offer higher throughput and greater flexibility than low speed systems, making them well suited to busy distribution, ecommerce, and fulfilment operations where accuracy and efficiency are critical. CSL Automation designs and delivers mid-speed sortation solutions that balance performance, footprint, and long-term reliability.
Options Include:
Interroll HPD • Intralox DARB • Uni-XU Switch Sorter • Mod Sort
High-Speed Sorters - Up to 20,000 p/h
Low SpHigh-speed sorters are designed for operations with demanding throughput, tight cut-off times, and a need for consistent, accurate destination sorting. Ideal for large-scale ecommerce, parcel, and distribution environments, CSL Automation’s high-speed sortation solutions are engineered to deliver maximum performance, reliability, and scalability.
Options Include:
Euro Sort (Cross Tray) • Euro Sort (Split Tray) • Intralox ARB • Interroll Split Tray Sorter • Interroll Crossbelt Sorter (Horizontal) • Interroll Crossbelt Sorter (Vertical)
Low to High Speed Sortation
Interroll Belt Transfer
Interroll Belt Transfer solutions provide high-speed, gentle, and reliable 90-degree sortation designed to maximise throughput and system uptime in demanding distribution environments.
Transfer speeds: up to 2.0 m/s
Cycle time: under 0.5 seconds
System throughput: 3,000+ units per hour
Maximum product weight: up to 50 kg
Divert capability: accurate 90-degree transfers
Benefits: gentle handling, low noise, reduced maintenance, energy-efficient
Low Speed - Uni-XU Chain/belt transfer
Uni-XU Chain/Belt Transfer solutions deliver robust, accurate, and flexible product diverting and merging for high-duty material handling and sortation environments.
Transfer speeds: up to 1.5 m/s
Cycle time: under 0.6 seconds
System throughput: 2,500+ units per hour
Maximum product weight: up to 75 kg
Divert capability: smooth 90-degree transfers
Product handling: cartons, totes, and irregular loads
Design benefits: modular, low maintenance, high durability
Low Speed - Itoh Denki F-RAT
The Itoh Denki FRAT machine is a compact, high-speed sortation and transfer solution designed to merge, divert, or align cartons and totes within automated conveyor systems. Using intelligent motor-driven rollers, it delivers precise 90-degree transfers with smooth, low-noise operation and minimal maintenance.
Performance highlights
High-speed right-angle transfers for cartons, totes, and cases
Motor-driven roller (MDR) technology for energy-efficient, low-noise operation
Compact footprint ideal for space-constrained layouts
Precise control for gentle product handling and accurate positioning
Scalable and modular design for easy system integration
Mid speed - Interroll HPD
Interroll High Performance Divert (HPD) systems deliver ultra-fast, high-accuracy sortation designed for demanding parcel and distribution operations.
Conveyor speed: up to 2.5 m/s
System throughput: 7,000+ units per hour
Sortation accuracy: high-precision, controlled diverts
Product handling: wide range of cartons and polybags
Divert performance: consistent angles, minimal product impact
Design benefits: energy-efficient drive, compact footprint, low maintenance
High speed - Euro Sort (Split tray sorter)
Euro Sort Split Tray Sorter systems from CSL Automation deliver fast, accurate, and gentle sortation for high-volume fulfillment and distribution environments handling diverse product mixes.
- System speed: up to 2.2 m/s
- System throughput: 9,000+ units per hour
- Maximum product weight: up to 35 kg
- Sortation method: controlled split-tray discharge
- Product handling: broad mix of product types
- Design benefits: compact layout, modular trays, energy-efficient operation
High speed - Euro Sort (Cross tray sorter)
Euro Sort Cross Tray Sorter systems from CSL Automation deliver high-speed, high-accuracy sortation for large-scale distribution and fulfillment operations handling diverse product ranges.
System speed: up to 2.5 m/s
System throughput: 10,000+ units per hour
Maximum product weight: up to 50 kg
Sortation method: precise cross-tray discharge
Product handling: wide range of sizes and weights
Design benefits: modular trays, energy-efficient drives, scalable architecture
High Speed - Intralox ARB
Intralox Activated Roller Belt (ARB) sortation systems deliver high-speed, accurate diverting and product alignment for a wide range of package types and applications.
Conveyor speed: up to 2.0 m/s
System throughput: 6,000+ units per hour
Maximum product weight: up to 45 kg
Divert angles: 30°, 45°, and 90°
Sortation method: continuous-flow ARB diverting
Design benefits: modular belts, low maintenance, energy-efficient, reduced noise
High speed - Interroll Horizontal Crossbelt Sorter
Interroll Horizontal Crossbelt Sorter systems from CSL Automation deliver ultra-high-speed, high-accuracy sortation for demanding parcel and eCommerce fulfillment operations.
Sorter speed: up to 3.0 m/s
System throughput: 20,000+ units per hour
Maximum product weight: up to 50 kg
Sortation method: continuous, bidirectional discharge
Product handling: wide range of product sizes
Design benefits: compact footprint, modular carriers, energy-efficient drive
High Speed - Interroll Crossbelt Sorter – Vertical
Interroll Vertical Crossbelt Sorter systems from CSL Automation deliver ultra-high-throughput sortation where elevation change and footprint optimisation are critical.
System speed: up to 2.8 m/s
System throughput: 14,000+ units per hour
Maximum product weight: up to 50 kg
Sortation method: vertical crossbelt with multi-level discharge
Product handling: wide range of product sizes
Design benefits: vertical layout, modular carriers, energy-efficient drives
High Speed - Interroll Split Tray Sorter
Interroll Split Tray Sorter systems deliver high-speed, high-accuracy sortation for large-scale parcel and fulfillment operations.
System speed: up to 2.3 m/s
System throughput: 21,600+ units per hour
Maximum product weight: up to 8 kg
Sortation method: controlled split-tray discharge
Application focus: parcel and fulfillment operations
Design benefits: modular trays, energy-efficient drives, scalable architecture, low noise
Our Approach
We deliver sortation as a complete solution—from application engineering to lifecycle support.
- Survey & Data Capture – SKU profiles, packaging types, arrival patterns, destination rules, peak/average volumes
- Concept & Simulation – layout options, throughput modelling, accumulation & recirculation logic
- Mechanical & Controls Design – sorter selection, conveyor interfacing, scanning/dimensioning, WMS/WCS integration
- Build, FAT/SAT & Commissioning – staged testing, on-site handover, training, run-rate ramp-up
- Service & Spares – preventive maintenance, remote diagnostics, upgrades and expansions
Typical Applications
- eCommerce Fulfilment Batch picking to destination sort, order consolidation, and intelligent exception handling—built for peak volumes.
- Parcel Hubs & Cross-Dock High-speed parcel routing by service level, size, or zone; efficient recirculation for no-read/duplicate labels.
- Retail Distribution Store-based allocation from totes/cartons; stable throughput with minimal damage and predictable waves.
- Manufacturing & Kitting – Component kitting and line-side sequencing; accurate routing to workstations with real-time control.
Integration & Data
- Identification: Barcode (1D/2D), RFID, and vision systems with multi-read strategies and no-read handling
- Dimensioning & Weighing: Inline measurement for compliance, charge-back accuracy, and sorter protection
- WMS/WCS & Middleware: Real-time handshakes, destination logic, exception routing, and performance reporting
- Dashboards & Analytics: Live KPIs (throughput, accuracy, no-reads, recirculation rates), downtime tracking, and maintenance alerts
Why Automate Sortation?
Manual sortation struggles with rising volumes, labour scarcity, accuracy demands and peak season spikes. Automated sorters provide consistent speed, precision, and flexibility, minimising mis-sorts, reducing manual touches, and enabling data-driven control across your fulfilment or distribution operations.
Key Outcomes:
- Higher throughput: 2,500 – 35,000 items/hour, engineered to your SKU mix and destination count
- Accuracy: Up to 99,9% precision with barcode/ RFID vision, and robust controls
- Labour Savings: Fewer manual touches and safer operations
- Scalability: Modular designs and destination expansion without disruption
Discuss your automation Project
Thank you for your interest in CSL Automation. As one of the UK’s leading conveyor and automation integrators, we can help design and install a system to help you take your business to the next level.
Start your automation journey today.
Explore our other solutions
Automated Returns
Multi-Floor Handling
Order Packing
Order Picking
Pallet Handling
Product Sortation
Product & Material Transit
Stock Replenishment
Product Sortation - Frequently Asked Questions
Which sorter is best for mixed SKUs and fragile items?
Cross-belt is typically preferred for accuracy and gentle handling; sliding shoe is excellent for speed with robust cartons. We validate with your product mix.
How do you handle no-reads and duplicate labels?
We implement multi-read scanning, exception lanes, manual QA points, and recirculation logic with WMS/WCS rules.
Can you integrate with our WMS/WCS?
Yes. We provide real-time handshakes, destination mapping, middleware if required, and dashboards for monitoring.
What maintenance is required?
Preventive maintenance plans include inspection, belt/chain service, calibration, and software health checks. We train your teams and can provide 24/7 support.
What floor space do we need?
Layouts are compact and modular; we design around your constraints and can use loop/recirculation strategies to reduce footprint while maintaining throughput.
How accurate is automated sortation?
With good label quality and scanning, up to 99.9% accuracy is typical. Vision systems and QA/no read lanes further enhance reliability.
