What is a pouch sorter – and how can it benefit my business?

However, logistics centre professionals need to be absolutely certain about the sorter’s capabilities, and whether it is a good match for their centre’s needs, before investing in one.

It is critical that they end up with an integrated system that manages all the steps in their ordering and returns processes, including manual or automated pouch loading with prepared returns, dynamic buffering for efficient material flow, and manual or automatic pouch emptying.

And most importantly, the logistics centre professional must fully understand how many items the system is actually capable of handling.

When the pouch system is a good fit for the logistics centre’s needs, and those of its key customers, it is an excellent solution that will enable the operator to fulfil orders quickly, accurately and cost-effectively while managing costs, labour shortages and space constraints.

What is a pouch sorter system?

A pouch sorter uses a network of suspended pouches to transport, buffer and sort individual stock-keeping units (SKUs).

The pouches are guided through a series of induction, buffering, sorting and unloading stages to optimise order fulfilment and returns processing.

A modern pouch sorter, which can sort up to 10,000 SKUs per hour per module, consists of the following key components:

• Induction station – where individual items are loaded into pouches, either by hand or automatically
• Buffer system – temporarily stores items in pouches, which allows for flexible release and efficient material flow
• Sorting mechanism – sorts items independently of the order structure, sequencing them for optimal packing. For example, utilising a 6³ matrix setup, the pouch system can sort 216 unordered items into a perfect order in 5 minutes
• Unloading station – the sequenced items are either deposited at packaging areas by hand or unloaded automatically from the pouch system.

Benefits of pouch sorters in e-commerce distribution

Pouch sorters bring a wide range of benefits to e-commerce distribution – again the impact of each one will very much depend on the needs and set-up of the logistics centre.

• Faster, more accurate order fulfilment – automation enables fulfilment centres to process and dispatch more orders per hour. Items are sorted and sequenced automatically, which reduces human errors and increases speed
• Batch picking optimisation – instead of picking items one order at a time, items can be picked in batches, which the system then sorts and sequences into individual orders. Overall this reduces the walking time of the pickers and boosts their efficiency
• Streamlined returns processing – returned items are fast-tracked into the buffer system, bypassing multiple manual handling steps. This means the returns are quickly ready for resale, which helps to reduce costs and turnaround times
• Space efficiency – the pouch system can make use of vertical space, making it a smart option for logistics centres with limited footprint
• Labour –  by automating sorting, sequencing and unloading, pouch systems reduce labour requirements and the risk of errors
• Peak season performance – scaling up to meet high demand is not a problem. During high-demand periods like Black Friday or Christmas, pouch systems can handle the peaks without extra staffing
• Seamless software integration – modern pouch sorters integrate with Warehouse Management Systems (WMS) and use technologies like RFID to track items accurately and manage complex order types with minimal difficulties

Real-world applications of pouch sorter technology

Pouch systems are already transforming the operations of leading e-commerce and retail businesses – notably modern logistics centres dealing with high volumes of small items, multiple returns and multi-item orders.

The increase in ‘smalls’ has posed a huge challenge to traditional sortation systems, but are a good fit for pouch systems, which enable efficient handling and sequencing – electronics and pharmaceuticals are two obvious beneficiaries.

The pouch system is also ideal for fashion and apparel businesses, as it can efficiently sort mixed-size, high-variety SKUs such as clothing, shoes and accessories – both single and multi-item orders, which are are packed in the correct sequence for optimal packaging.

However, not all logistics centres will benefit to the same tune. If low orders and bulky items are the norm, for example, it’s unlikely a pouch system will deliver on the investment.

To be absolutely sure of their investment, logistics centres must assess both their needs and future needs – preferably with the help of an experienced system provider.

Considerations before implementation

A pouch system can dramatically improve the performance of a logistics centre, but only if it matches specific operational needs.

Before investing in a pouch system, therefore, careful consideration should be given to this – starting with the throughput.

Often, during negotiations, the meaning of ‘throughput’ can be confused: is the vendor talking about the technical throughput or system throughput?

Clarification is essential as the system throughput, the achievable performance in live operations, is 15-20% lower than the technical rate and it might be lower than the logistics centre’s peak needs.

Integration is another important consideration, as not only should the system chime with all the processes – manual or automated – but it must integrate seamlessly with the WMS and any existing tracking or diagnostics platforms.

And finally, the ROI – will the logistics centre’s savings justify the investment?

TAKEAWAY

Pouch systems are increasingly becoming the sortation solution of choice for modern logistics centres dealing with high volumes of smalls, returns and multi-item orders – and for good reason. To such an environment, they bring untold flexibility, optimising the speed, accuracy and labour use of the logistics centre. However, not all centres would substantially benefit, and that’s why careful consideration should be given – preferably with the help of an experienced system provider.