THE CHALLENGE
A leading 3PL logistics provider was facing rising labor costs and increasing order inaccuracies driven by a manual sortation process handling approximately 1,200 packages per hour. The existing operation could not scale to meet seasonal peak demand, resulting in shipping delays, customer complaints, and limited ability to flex capacity across regional sites.
THE SOLUTION
Regal Rexnord delivered a modular, automated sortation system designed to handle mixed parcel flows without manual intervention. The solution incorporated MDR conveyors, ModSort™ diverts, and an intelligent control system - including scanners - to automate sorting while seamlessly integrating with the warehouse management system. The compact, mobile design allowed the solution to fit within the existing footprint and be redeployed quickly across the customer’s regional 3PL locations as demand shifted.
Services Provided:
- In house factory acceptance testing (FAT)
- Mechanical and electrical installation
- Software commissioning
- Site acceptance testing (SAT)
A WINNING OUTCOME
- 150% throughput increase, scaling from ~1,200 to ~3,000 packages per hour
- 99% sorting accuracy, improving customer satisfaction and order quality
- Four full‑time employees redeployed to higher‑value roles
- $500,000 in annual labor savings
- Faster responsiveness to seasonal demand peaks without additional headcount
THE BENEFIT
The system eliminated manual sorting touches, significantly increased peak capacity, and reduced maintenance requirements through a no‑pneumatics design, cutting maintenance needs by 50%. The modular architecture enabled rapid deployment and flexibility without disruption to existing operations.
