How Pouch Sorters Can Enhance Warehouse Efficiency

Key takeaways

1. A pouch sorter is a conveyor system comprised of hanging pouches, pockets, or carriers that move products along a rail.
2. Pouch sorters work well with warehouse management systems and other technologies, creating a cohesive sorting environment.
3. The technology leads to long-term financial benefits by making the returns process easier.
4. Integrating a pouch sorter with AutoStore can enhance buffering and sequencing capabilities of customer orders and returns.
5. A real-world example of an AutoStore+pouch sorter integrated warehouse automation solution

What is a pouch sorter?

A pouch sorter, also known as a pocket sorter, is a sophisticated sortation system designed to automate the process of sorting items within a warehouse or distribution center. At its core, it is a conveyor system comprised of hanging pouches, pockets, or carriers that transport products along a rail. It is designed to transport a wide range of items, including hanging garments, flat-packed items, shoes, books, and general merchandise.

The core functionality of a pouch sorter revolves around its ability to streamline the sorting process by reducing manual handling and increasing throughput.

To understand how pouch sorters fit into the broader logistics landscape, it's important to look at their integration within existing sortation systems. While pouch sorters themselves are sophisticated, relying on a network of pouches to automate sorting, their effectiveness is greatly enhanced when they seamlessly connect with other warehouse technologies.

How pouch sorters integrate into a sortation system

Pouch sorters seamlessly integrate into existing sortation systems by working in conjunction with other warehouse technologies. Typically, they connect with warehouse management systems (WMSs), which send waves with orders and the sequence within an order, if necessary.

This integration ensures that pouch sorters operate efficiently within the broader warehouse ecosystem, coordinating with other automated systems and manual processes to maintain a smooth workflow. By combining with technologies such as barcode scanners or radio frequency identification (RFID) systems, pouch sorters enhance overall operational efficiency and accuracy, creating a cohesive and responsive sorting environment.

Key benefits of pouch sorters in order fulfillment

Operational efficiency and speed  

Pouch sorters transform warehouse workflows by significantly improving operational efficiency and speed. Unlike traditional sorting methods that rely on manual labor or slower mechanical systems, pouch sorters automate the entire process. However, the average order process time of a pouch sorter is approximately three hours. While they cannot process orders quickly, they're advantage is the ability to process a high number of orders in parallel.

Safety, ergonomics, and worker comfort  

In addition to improving operational efficiency, pouch sorters contribute to a safer and more ergonomic working environment by reducing the physical strain associated with manual sorting tasks. With automated systems handling the bulk of the sorting work, employees are less likely to experience repetitive strain injuries or accidents related to manual handling.  

The system's design allows workers to operate in a more controlled environment with less need to constantly move items. These ergonomic benefits lead to lower rates of workplace injuries, increased job satisfaction and a more comfortable workplace overall. A drawback is the maximum weight capacity of 11 to 17 lbs (5 to 8 kg) per pouch, which does not support heavy or bulky or heavy items.

Cost savings and long-term financial benefits

Investing in pouch sorters provides substantial long-term financial benefits through cost savings and a strong return on investment (ROI). The initial investment in pouch sorter technology is often offset by the significant efficiency gains and error reduction it delivers. By improving sorting speed, accuracy, and overall operational efficiency, pouch sorters help lower costs associated with:

• Returns: Fewer errors result in fewer returned orders.
• Rework: Enhanced accuracy minimizes the need for reprocessing incorrect orders.
• Customer dissatisfaction: Reliable fulfillment leads to better customer experiences.

Furthermore, the reduction in manual labor lowers labor expenses and contributes to higher productivity. Over time these savings accumulate, making pouch sorters a financially advantageous investment for businesses seeking to optimize their warehouse operations.

With the benefits of pouch sorters — such as improved accuracy, speed, and efficiency — clearly outlined, it's evident how they enhance order fulfillment. Next, let’s see if a pouch sorter is the right fit for your business, evaluating key factors to determine its suitability for your specific needs.

Is a pouch sorter right for your business?

Operational considerations

Determining whether a pouch sorter is suitable for your warehouse operation involves assessing several key factors:

• Product types: Ideal for small, lightweight items. For larger or bulkier items, other technologies might be better.
• Warehouse size and layout: Pouch sorters optimize space with vertical storage. Ensure your warehouse layout can support the required infrastructure.
• Order volume and complexity: Best for high numbers of orders and complex sorting needs. Assess if it matches your operational demands.
• Scalability: Pouch sorters are not easily scalable. When they reach their peak performance you need to buy a whole new matrix.
• ‍Adaptability: Because the pouches are only able to handle SKUs up to certain dimensions and weight, they are not typically adaptable to your various product types and integration needs.

Solution-fit assessment: your checklist

To drill down further in your assessment, your business should meet these general criteria to become a candidate for pouch sortation:

Having evaluated whether a pouch sorter is the right fit for your business based on operational considerations and scalability, it’s essential to look at how other technologies can further enhance your order fulfillment.

AutoStore + Pouch Sorter: a holistic combination for a high-throughput environment

The AutoStore system can easily integrate with any pouch sorter system. This capability has been tried and tested by several fashion, retail, and e-commerce customers around the globe. AutoStore focuses on inventory storage, retrieval, and space optimization. The addition of a pouch sorter enhances buffering and sequencing capabilities of customer orders and returns.

What are the benefits of integrating a pouch sorter with AutoStore?

10x boost in operator productivity
Common SKUs shared across multiple orders can be picked in batches from one Bin presentation. This "high batch factor" reduces the number of Bin presentation required. Coupled with AutoStore's dynamic Robot allocation strategy, where operators at picking stations never wait in between Bin presentations, it greatly enhances the pouch infeed speed from 120 pieces/hr in a pick tower + pouch sorter configuration to up to 1,200 pieces/hr.

Increased order consolidation efficiency
‍Items are completely independent from order structure and picked in waves ("item-by-item sequence"). By leveraging the dynamic buffering and sequencing capabilities of the pouch sorter together with AutoStore's robotic retrieval system, it enables the handling of large quantities of orders and overall solution throughput with remarkable accuracy.

Faster and effective returns handling

• A-mover returns: Quickly reintegrated directly into the dynamic buffer where they immediately become available and prioritized for outgoing orders.
• B/C-mover returns: Stored back in the AutoStore Grid for space-efficient storage until required if no immediate order is available.

Parallel order processing of different sales channels in one solution
‍Both B2C/D2C and B2B orders can be picked from the same workstations:

• B2C/D2C: AutoStore utilized as storage system.
• B2B: Large volume B2B orders for retail and wholesale top-off will be pick-and-packed directly at the AutoStore workstation to avoid unnecessary buffering.

Maximized warehouse space utilization
‍All items will be stored in AutoStore Grid, which by design has the highest storage density ratio of any ASRS — up to 4x compared to a conventional storage system — allowing optimal use of your limited storage space. By having the AutoStore occupy the lower levels of a warehouse and the pouch sorter utilize the unused overhead space, you can fully exploit the unseen vertical space, making it an ideal solution for space-constrained operations.

The AutoStore+pouch sorter solution: A real-world example

Fenix Outdoor Logistics, which manages distribution for renowned outdoor brands such as Fjällräven, Hanwag, Primus, Royal Robbins, and Tierra, uses a pouch sorter as part of its overall warehouse solution in
Ludwigslust, Germany.

Its AutoStore Grid connects seamlessly to a pallet warehouse for overstock management on one side. On the other side, it connects with the pouch sorter, manual preparation area, and semi-automated packing stations to creates a cohesive, end-to-end process flow that optimizes order fulfillment for both e-commerce and store replenishment channels.

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Does an AutoStore+pouch sorter combination fit my business needs?

To further explore the AutoStore+pouch sorter solution, speak to an AutoStore systems integration partner that can explain your options. You can also book a free 30-minute consultation meeting with an AutoStore System Design Analyst who can provide a 3-D simulation of your
optimal warehouse layout.

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Conclusion

Pouch sorters are transforming warehouse operations by automating sorting, improving accuracy, speed, and efficiency while reducing manual handling. They integrate seamlessly with existing technologies to enhance overall workflow and accuracy. Evaluating their fit for your business involves considering factors like product types and warehouse layout. The AutoStore system integrates easily with pouch sortation and is used by fashion, retail, and e-commerce customers around the globe. AutoStore provides these customers with inventory storage, retrieval, and space optimization benefits. The addition of a pouch sorter enhances buffering and sequencing capabilities of customer orders and returns.

FAQ

What is a pouch sorter?  

A pouch sorter is an automated system that uses a network of pouches to transport and sort items efficiently within a warehouse or distribution center.

What is a sorter system?  

A sorter system is a technology designed to automatically organize and route products or items to their correct destinations based on predefined criteria.

What is a sorter used for?

Sorters are used to streamline the sorting process in warehouses or distribution centers, improving efficiency, accuracy and speed in handling and delivering items.

Can I integrate an AutoStore system with a pouch sorter system?

Yes, you can. In fact, this type of warehouse automation solution is used by several fashion, retail, and e-commerce customers around the globe. Typically, these businesses sell a high volume of fast-moving hanging garments, flat-packed goods, and other items commonly found in e-commerce and omnichannel applications within fashion and retail.

What are the benefits of integrating a pouch sorter with an AutoStore system?

You achieve the same benefits as a standalone AutoStore system (cost efficiency, speed, scalability, and density), plus more, for any mix of small to large orders. The combination is an effective solution for overcoming challenges faced within a fashion and retail distribution center.