Split tray sorter enables fast returns

At peak times the mail order company processes up to 77,000 orders per day to a customer base of some nine million consumers. The product range includes women’s and men’s clothing, shoes, household articles, textiles and accessories. Returned goods are a significant challenge in eCommerce and mail order logistics. The Dürkopp split tray sorter is designed to make it easy to re-stock returned goods.

In the past, a cross belt sorter was used to process the returns, however increasing maintenance costs and equipment down time reduced productivity, and the equipment no longer met the required performance standards. Following a review of several options, Witt then decided to invest in the split tray sorter system. During the two month installation and commissioning period, the old system continued to be used in parallel so there was minimal disruption to the business.

Now the returns process starts with the goods being checked manually and then re-packed for re- stocking. The split tray sorter enables returned stock to be automatically inducted by two induct stations in any order onto the split tray sorter where it is recognised by the control system and directed to the appropriate drop-off location to be stored away.

The sorter trays have a dimension of 60x60 cm which enables stock to be loaded in almost any orientation – for example, shirts and trousers can be inducted lengthways or sideways which further increases the system’s speed of 1.3 m/sec.

The 24 chutes are also designed so that each one can discharge goods into two separate storage boxes which effectively doubles the sorter capacity. Following the sortation process, employees then scan the article and move it into tote bags for storage until re-ordered.

Annette Sommer, UK general manager for Dürkopp, said: "I am delighted the split tray sorter has surpassed the required performance criteria of Witt Weiden. The system can also be easily expanded so providing additional capacity to meet future business demands.”