Automated sortation systems bring together barcode scanning technology, conveyor systems and bespoke software controls, to provide a high-speed reliable sorting solution. They eliminate the time and costs associated with manual sorting – loads are simply scanned and programmed logic either moves them onto the next area of the conveyor process, or sorts them into their relevant lanes for packing and dispatch.
Keymas are experts at designing and delivering sortation systems – both linear and re-circulating solutions.
We’ll spend time getting to know your business and find a system that fits the exact requirements of your space and throughput. By automating the sorting and dispatch of your operation, you can speed-up operations, improve accuracy and be more responsive to market demands.
Advantages of effective conveyor sortation systems:
Precision. Speed. Flexibility.
Efficient sortation is at the heart of any high-performing warehouse. Our advanced warehouse sortation systems are designed to streamline operations, reduce manual handling, and maximise throughput—whether you’re handling parcels, totes, cartons or polybags.
We design, integrate, and support custom sortation solutions that scale with your operation.
Our cross belt sorters offer fast, bi-directional sorting for high-volume, high-accuracy environments. Ideal for distribution centres and e-commerce operations, they deliver precise item placement and can handle a wide range of product types and sizes.
High throughput and low error rates
Modular, scalable design
Supports integration with scanners, weighers and dimensioning systems
Popup sorters are a versatile solution for diverting items at 90° or 30°, often used in conveyor systems where space is limited. They’re perfect for mid-speed sortation of consistent product sizes.
Quick and reliable product diversion
Compact footprint
Easily retrofitted into existing systems
Our swivel sorters offer dynamic sorting with minimal impact on flow. Using angled wheels, they smoothly divert products left or right without stopping or lifting.
Quiet, low-maintenance operation
Ideal for fragile or lightweight goods
Flexible routing with minimal disruption
Our ecommerce and mail sortation systems are built to sort orders being sorted into various despatch lanes. Our software comes with integrated barcode reading and sortation lane logic. The modular approach we use allows it to built to fit various sizes of soration. From a small 4 way sort to 100 lanes+, the Keymas sorter solution give’s a fast sorter speed while keeping install and running costs down.
| Feature / Benefit | Cross Belt Sorter | Popup Sorter | Swivel Sorter |
|---|---|---|---|
| Best for throughput | Very high (6,000–20,000+ pph) | Medium (2,000–6,000 pph) | Medium–High (4,000–8,000 pph) |
| Gentle product handling | Excellent – controlled belt discharge | Moderate – depends on product | Good – smooth angled discharge |
| Handles mixed item types (bags + cartons) | Excellent | Limited | Very good |
| High number of destinations | 50–200+ | 10–40 | 20–80 |
| Bidirectional sorting | Yes | Usually one-sided | Yes |
| Layout flexibility | Oval, linear, multi-level | Inline systems | Flexible angles |
| Scalability | Modular, easy to extend | Limited by conveyor layout | Modular sections |
| Maintenance complexity | Higher complexity | Simpler | Moderate |
| Capital cost level | High | Medium | Medium–High |
| Best application | Large e-commerce and parcel hubs | Carton-only distribution | Mixed parcel distribution |
Strengths:
Typical Use Case:
National fulfilment centres, parcel carrier hubs, large omni-channel DCs.
Strengths:
Limitations:
Not ideal for polybags or unstable loads.
Typical Use Case:
Retail carton distribution, case handling.
Strengths:
Good speed and accuracy
Typical Use Case:
Mid-sized e-commerce, 3PL operations.
As part of our modular system other options such as inline weighing and print and apply can be added as needed. If your project requires 5 sided scanning or adding labels automatically onto the items then we can tailor the system to work for your needs.
We can provide expert advice and bring our knowledge and experience to your project.
Contact us about your projectKeymas Ltd, Office 3 Wassell Grove Business Centre, Wassell Grove Lane, Hagley, Stourbridge, West Midlands, DY9 9JH UK
Keymas Limited is company registered in England and Wales with Company No. 2029255
