Automated Conveyor and Sortation Systems

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Automated Conveyor and Sortation Systems

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The Automated Conveyor and Sortation Systems offer reliable and efficient order processing while being the heart of a modern distribution center. Russell Conveyor & Equipment provides a range of conveyor sortation systems guided by advanced software to optimize warehouse operations and supply chain demand.

Leading retailers and other distributors trust Russell Conveyor & Equipment to produce rapid, accurate, and cost-effective Sortation solutions. With increasing labor costs and demand for faster, more productive operations, Russell Conveyor & Equipment improves productivity, throughput capacity, and distributors’ accountability.

Benefits of Russell Conveyor & Equipment Sortation Systems:

  • Increase output 
  • Improve order accuracy 
  • Develop cross-docking processes 
  • Employ zone-skipping strategies 
  • Automate end-of-line palletizing operations 
  • Integrate with warehouse execution systems 
sortation conveyor

Providing intelligent solutions to everyday problems, the sorting conveyor pushes products down the conveyor line. Without using a warehouse sorter in a distribution setting, the cartons would need to move manually, slowing production. The Sortation Conveyor system will meet the growing demand for any distribution that needs to fill order sizes. These conveyors are best suited for high throughput operations that require products to flow to numerous locations, from smaller operations to productions with a high shipping accuracy with frequent shipments.

What is the Automated Sortation Conveyor Systems:

The Automated Sortation Conveyor System uses conveyors, diverters, and warehouse management software (WMS) while providing a smart sortation solution. Using a sortation system, a merging method and software, the Sortation Conveyor System moves products accurately. These components combined can increase efficiency and accuracy. This component allows warehouse management to cut labor and maintenance costs. The sortation conveyor moves cartons from point A to Point B within the warehouse. The sortation conveyor diverter uses a type of technology to divert cartons down the conveyor line. A Merging method tracks identify and transport these materials throughout the entire process, which prevents products from getting lost. Warehouse sortation allows lowers labor costs as it doesn’t require as many operators. Our systems are modular by design, allowing you to expand as demand grows. This solution is ideal when you need to increase throughput and decrease labor costs.

What is a Sortation Conveyor?

The Sortation Conveyor, also known as the Automated Sortation Conveyor System, uses a zero-pressure accumulation method to gather cartons into a corral. The zero-pressure accumulation is ideal because it prevents products from being damaged. Using the merging method, The Sortation Conveyor will then identify, weigh, and arrange the cartons. The Sortation Conveyor does this by scanning products as they come down the lane. Next, it diverts the cartons to the designated route and onto the process in production. The Sortation Conveyor increases productivity by implementing a warehouse sorter that sorts products and sends them to the designated area. The computer technology is easy to program, allowing customers to speed up or slow down the sortation conveyor without a hassle. We offer a wide range of pallet management and reverse logistics solutions. 

warehouse sorter

What does a Sortation Conveyor Diverter do?

The Automated Sortation Conveyor Systems uses a bar code scanner system to place cartons in an accumulation holding area, and then the cartons take turns moving into predestined lanes. This conveyor product can divert at 30 degrees, 45 degrees, or even 90 degrees. Our sortation conveyors are High-Quality products and contain MDR technology. At Russell Conveyor & Equipment, we can guarantee our conveyor system will save the company time and money. It will cut power costs down by 75 percent and reduces noise output within the facility. 

What makes the Automated Sortation Conveyor the ideal warehouse conveyor?

The Automated Sortation Conveyor Systems integrates an introduction system, system merging, and sortation diverting methods to accomplish this goal. This conveyor system uses this system because it gets products where they need to be. The Sortation Conveyor fits every operation’s need to identify, track, and transport products, making production flow without disruption. The sortation conveyors work best for operations with high output that require products to flow to different locations. The Sortation conveyor that will be the right fit for your operation will depend on the size, the weight of the products, and how heavy the output traffic will be throughout the distribution.

How does the Automated Sortation Conveyor Systems operate?

The Sortation Conveyor is a warehouse conveyor that separates products by sending cartons down to pre-designated lanes to arrange and accumulate. This increases productivity because the conveyor moves faster than an operator. The Sortation Conveyor is optimized when high quantities of products need to flow in different directions. This warehouse conveyor system is to expedite the packing and shipping process at an efficient rate. The identification process can only happen through a series of bar code scanners or a “round-robin” situation moving cartons into pre-determined lanes. The diverting type most commonly used with the sortation conveyor diverter is a Pop-Up Divert. 

Itoh Denki Pop Up diverter module

Itoh Denki Pop Up diverter

The Sorting Conveyor is the ideal solution for separating products from the in-feed conveyor lines. The sortation conveyor does this because the sortation conveyor diverter can divert those products down multiple shipping lanes. The diverter can send cartons down the line using photo-eye technology. The Sortation Conveyor is versatile because it sorts through a wide range of product sizes and weights. The Sorting Conveyor can meet growing demands on the production floor. These challenges can range from small order sizes to increased accuracy in shipping productivity. Conveyors are essential for moving products from one area of a facility to the next because the sortation systems separate products into individual lanes typically associated with an outbound destination. Various types of sorting conveyors are often connected to create a fully functioning material handling solution.

The reason the Warehouse Sorter is gaining popularity?

To increase production, the Sortation Conveyor needs to transport products and move items for store replenishment quickly. Operators alone are no longer enough to keep up with the demand of e-commerce, which has caused distributions to handle the needs of rising e-commerce by updating their sorting conveyor system. The Automated sortation conveyor systems address a wide range of these emerging challenges:


  • Increase output to keep up with high order volumes and use SKU proliferation
  • Improve order accuracy to minimize the returns from processing
  • Develop cross-docking processes to alleviate storage and handling problems
  • Employ zone-skipping strategies to mitigate shipping costs and to expedite deliveries
  • Automate end-of-line palletizing operations for manufacturing 
  • Integrate with warehouse systems to drive greater levels of automation

Does the Sortation Conveyor Diverter feature?

Some of the Sortation Conveyor Diverter Features are as follows:

  • Sweeper sorters
  • Cross-belt sorters
  • Tilt-tray sorters
  • Push tray sorters
  • Strip-belt sorters
  • Popup wheel sorters
  • Bomb bay sorters
  • Vertical sortation systems
  • High-speed sorters

The Automated Conveyor and Sortation Systems can accommodate small spaces while providing flexibility. First, the Automated conveyor offers a zero-pressure accumulation technology with the sorting conveyor that moves products without being damaged. Secondly, this happens because the zero pressure move products without touching by using photo-eye technology. The warehouse sorter can accommodate for inclines or declines within production. The warehouse sorter has gained so much popularity because of its ability to make production lines run smoother and faster while decreasing product damage. While it may be an initial investment in the long run, with its ability to reduce production time and product damage, it will save companies millions in the end. 

Why choose Russell Conveyor for your Automated Sortation Conveyor?


Russell Conveyor & Equipment provides sturdy and versatile sorting conveyors and offers warehouse sortation systems. These systems address the increasing rise of economic and commerce problems. The Russell Conveyor team values building long-lasting relationships, and; we can guarantee that we will offer only high-quality conveyors. The conveyors can accommodate any spacing size. Our Sortation Conveyors can include but aren’t limited to the following:

When used effectively with existing material handling operations conveyors, move products, sort products, and convey full pallets of goods throughout the facility. This method solves the problem of the increased demands for products needing to reach the consumer faster. Our Sortation conveyors move quickly and get products to the consumer without causing damage or becoming lost. 

Automated Sortation Conveyor Systems: The warehouse sorter solution 


The Automated Sortation Conveyors is the accurate sortation system. They provide intelligent solutions to everyday distribution problems because the sorting conveyor pushes products down the conveyor line. Without using a warehouse sorter in a distribution setting, the outcome would need to move manually, slow production. The Sortation Conveyor system will meet the growing demand for any distribution that needs to fill order sizes. These conveyors are best suited for high throughput operations that require products to flow to numerous locations, from smaller operations to processes with a high shipping accuracy with frequent shipments.

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