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Individual solutions for heavy loads

Cranes are used in many industries. Steel producers, recycling yards and companies from the construction industry VAHLE offers reliable systems for energy and data transmission.

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Automated conveyor technology in the internal flow of goods

Increasing production rates, high throughput volumes and short delivery times require partially or fully automated intralogistics.

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Innovative solutions for flexible production processes

Adaptable manufacturing processes are the key to the greatest possible efficiency in vehicle production. VAHLE solutions for energy and data transmission make a significant contribution to this.

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Innovative solutions for the ports of tomorrow

Zero emission is the requirement for the port of the future. With the solutions for energy and data transmission from VAHLE, port operators are getting closer to this goal.

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Intelligent solutions for the rides of the future

The amusement, leisure and adventure sectors are often at the cutting-edge of the industry. That's why many ride builders and manufactures rely on VAHLE to provide roller coaster and ride passengers with increasingly extraordinary experiences. 

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Automated transport systems for the mobility of the future

Streetcars, sky trains or rolling sidewalks are the future of resource-saving mobility. Many manufacturers rely on components from VAHLE for the design.

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Innovative solutions for special mobile applications

Stadium roofs, waste incineration plants, facade elevators: Mobile industrial applications are used in many areas. VAHLE offers various special solutions for reliable energy supply and data communication.

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Data communication: fast, flexible and secure

Advancing digitization requires the transmission of ever greater volumes of data. Our vCOM solutions ensure reliable data communication for the control of automated conveyor systems at all times.

Solutions for data communication
Positioning: robust, flexible and precise

Modern manufacturing requires automated conveyor systems that can be positioned with extreme precision. The prerequisites for this are created by our robust vPOS solutions, which are available with both magnetic and optical processes.

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Control: mobile, scalable and efficient

Automation is shaping modern production processes more than ever. Numerous mobile conveyor units must be reliably controlled. With our versatile vDRIVE solutions, this can be achieved flexibly and with optimized performance.

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System solutions: Everything from a single source

With our holistic system solutions, we offer a perfectly coordinated product combination of power transmission, data communication, positioning and control for a wide range of applications.

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Sorter systems

The ultra-marathon-runners of logistics: modern sorter systems

Just imagine: A sorter system runs all year round, 24 hours a day, without a break. How many kilometers will it cover? Sorter systems are among the most impressive technical systems in modern logistics. At a speed of up to 3 meters per second, they move millions of parcels, letters and pieces of luggage every day. Whether in ultra-modern online retail distribution centers or at hectic airports, they work around the clock, 365 days a year.

Their ability to sort an enormous volume of items precisely and efficiently makes them the indispensable backbone of intralogistics. In one year, a sorter system travels over 94,000 kilometers at a speed of 3 meters per second and round-the-clock operation. That's more than twice the circumference of the earth!

The challenges for sorter systems

Continuous operation under extreme conditions

Sorter systems are the marathon runners of logistics - they have to work around the clock with an availability of over 99%. Especially on peak days such as Black Friday or during the holidays, they run at full speed. The aim is to sort thousands of parcels per hour without errors. Any failure can bring the entire supply chain to a standstill and cause high costs.

  • Resistance to external influences: Sorter systems must also work reliably under dust, temperature fluctuations and high humidity.
  • High resilience of components: Mechanical parts must be designed to withstand millions of cycles in order to avoid failures.

Maximum precision in fractions of a second

A sorting error costs time and money. That's why modern systems have to make decisions in milliseconds. Automated detection, intelligent sensor technology and automated processes ensure error-free and efficient sorting - even at maximum speed.

  • Minimize error tolerance: Even the smallest deviations in sorting can lead to massive delays and returns.
  • Real-time data processing: Systems have to analyze and process large amounts of information in milliseconds.

Increasing efficiency through smart technologies

Minimal maintenance with maximum uptime - a key success factor for economical sorting systems. Energy-efficient solutions lower consumption and reduce CO₂ emissions. At the same time, the increasing use of automation and robotics enables processes to be optimized and bottlenecks to be managed proactively.

  • Predictive maintenance: Intelligent maintenance systems detect wear at an early stage and prevent unplanned downtime.
  • Resource-saving operation: Reliable control systems lower energy consumption and reduce material wear

Flexibility and adaptability

Logistics is becoming increasingly dynamic - sorter systems have to efficiently handle a wide variety of parcels in varying shapes, sizes and weights. At the same time, the market requires rapid adaptation to new product ranges and customer requirements. Flexible configurations and scalable systems are therefore essential.

  • Modular expandability: Systems must be able to be adapted to new requirements with minimal effort.
  • Multi-format capability: Sorter systems must be able to recognize and efficiently process a wide variety of packaging and product sizes.

Seamless integration and system compatibility

Digitalization places high demands on the IT infrastructure of logistics centers. Sorter systems must be able to be integrated smoothly into existing processes. Standardized interfaces facilitate communication between machines and systems and enable end-to-end networking.

  • Interoperability with other automation solutions: Efficient collaboration with robotics, conveyor technology and merchandise management systems is crucial.
  • Simple scalability: IT and control systems should be able to be flexibly expanded as throughput increases.

Economic efficiency and future-proofing

Investments in sorter systems must pay off in the long term through efficiency gains and cost savings. Scalable solutions ensure that companies can react flexibly to growth and continuously optimize their logistics processes.

  • Low operating costs: Energy-efficient drives and intelligent control systems help to reduce costs in the long term.
  • Investment protection: Future technology upgrades should be compatible with existing systems to ensure long-term profitability.
     
The diversity of sorter technologies

The right solution for every scenario

Choosing the right sorter system is crucial to the success of a system. Each of these systems offers specific advantages and is optimized for different logistics requirements.

Cross Belt Sorter

These sorters use individual belts that run over rollers and are capable of sorting different items at the same time. They are particularly efficient at handling small and medium-sized parcels and offer high speed and precision.

Tilt Tray Sorter

The Tilt Tray Sorter system uses tilted trays to direct products in different directions. These systems offer a high degree of flexibility and are ideal for sorting large, irregularly shaped goods.

Sliding Shoe Sorter

With moving shoes that transport the products along a fixed route, this sorter is particularly suitable for small to medium-sized items. It is characterized by high precision and speed, even with complex sorting requirements.

Steerable Wheel Sorter

This technology uses steerable wheels to move products along defined paths. Steerable wheel sorters are particularly suitable for applications where different product sizes and weights need to be handled.

Pouch Sorter

Pouch sorters use small pockets to sort and transport products. They offer a high degree of flexibility and can be used in various industries, particularly for handling textiles, small parts and pharmaceuticals.

Pusher or Puller Sorter

This type of sorter is used to either push or pull products and transport them to the desired location. They are ideal for handling heavy or large goods that require strong mechanical support.

93,661 kilometers per year

The impressive performance of sorters

A sorter system that operates at a speed of 3 meters per second and is in operation 99 percent of the time covers a distance of around 93,661 kilometers per year. This is more than twice the distance around the equator. In other words, you would have to drive at a constant speed of 120 km/h for 32.5 days to cover the same distance. These impressive figures illustrate the high demands placed on the robustness and durability of sorter systems.

Sorter systems are exposed to extreme loads - day after day, without a break. But how do you ensure that these systems require as little maintenance as possible and are extremely durable at the same time? A maintenance-free system reduces downtime and maintenance costs. You don't have to constantly reckon with expensive repairs, but can rely on the systems always being ready for use.

The key to top performance

The right energy transfer

Despite the large number of suppliers and sorter systems, there is one area in which customized solutions still play a decisive role: the right power transmission. Many suppliers offer sorter systems, but rarely are solutions offered that meet the highest requirements - for example through UL certification and customization to specific needs. It is particularly important to differentiate between inductive and conductive energy transmission in order to maximize performance and efficiency.

This is where VAHLE comes in: With reliable, durable and low-maintenance energy transmission technology, we ensure that sorter systems not only work efficiently and reliably, but can also cope with the most extreme requirements. Particularly in the age of growing e-commerce, where sorter systems are becoming ever more powerful, tailor-made solutions are required that guarantee maximum efficiency with minimum CO₂ emissions.

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Inductive energy transmission

CPS140

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Conductive energy transmission

U20

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Conductive energy transmission

U10

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Innovation magazine

VAHLE Visions Intralogistics

Always up-to-date and always provided with the latest innovations and technology news from intralogistics.

Discover trends and future prospects and find out how VAHLE is advancing the industry with its progressive solutions and promoting sustainable developments. Benefit from exclusive insights into the world of modern intralogistics.

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Your Vision. Our Solution.

Together we solve challenges

Our team of experts is on hand to answer your questions and help you with any challenges!

We have an answer to all your questions and will support you with your sorter system.

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