Project
Logistics
Year
2025
Distribution centre conveyors
Conveyor retrofit and sortation logic for a peak-season distribution centre.
Headline result
2.1×
Peak throughput
Orders / hour
1.8k
3.8k
+111%
Mis-sorts
1.2%
0.3%
−75%
The challenge
A regional distribution centre could not ship its peak-season volume. The conveyor loop jammed at the sorter merge, and mis-sorted totes were sent back by hand.
What we did
We modelled the flow with a year of real order data, added accumulation buffers before the merge and rewrote the sortation logic so totes are released in waves.
The retrofit went in over three weekends, without losing a shipping day.
The result
Peak throughput went from 1,800 to 3,800 orders an hour in the same building, and mis-sorts fell from 1.2% to 0.3%.
Next step
Have a line that should be doing better?
Tell us what is slowing it down. An engineer replies within one business day with a first read on where the time is going.