RollerBall® Case Studies

Real-life examples where these innovative sorters are making a difference.

Package Sorting for Last-Mile Delivery

Original layout of delivery unit with 20 modules

Installed in one day, operational on day two. This versatile sorter has been in daily operation since its April 2018 commissioning, and has already handled almost 4 million packages. Four more sort points were added months after installation. The new sorter section was installed, “plug-and-play”, in less than 4 hours. This system sorts a variety of boxes, bags, envelopes and pillow packs into hampers at rates of over 1,800 per hour.

  • Compact footprint fits into a crowded delivery unit
  • Quiet, dependable operation
  • Intuitive operation, no significant training required
  • Custom interface to Postal sorting server
View of delivery unit sorter as installed

With minimal training, clerks quickly learned how to operate the sorter and became proficient in feeding the wide variety of packages and shapes. Illuminated touch buttons, illuminated scanner targets, and audible read confirmation make sorter operations intuitive.

Site personnel have been particularly pleased with the low noise level of the sorter and how the sorter will wait in standby, always ready to run whenever anyone had packages, even with a single operator.

Sorting Express Packages into Sacks

Express mail sack sorting layout

This application called for sorting envelopes and small packages into sacks. Limited floor space required maximum efficiency from the sorter layout to provide over 100 sort separations. The scanner reads a variety of barcodes, but weight and dimensions are not currently needed.

Smaller RollerBall® zones are used, arranged in a U-configuration. Two right angle turns are used for most efficient use of space. The induct does not include a scale or dimensioner, but adds an extra buffer zone to accommodate delays in communicating with an external sort server.

Routing and Applying Labels

Shipping label application and routing

This sorter is part of a micro-fulfillment operation. It includes scanning, weighing and labelling. This system supports route optimization, with the potential to spread shipments across multiple shipping companies, and automatically sort by shipper.

The scanner reads an order number for each package, and looks it up in the manifest system. The weight of the package and its order information are used to determine the shipping route. The appropriate shipping label is printed, applied and verified. The package is then sorted into hampers based on shipping provider and dispatch window.