04. Automation of Sorting 6,000 Parcels per Hour for an 8,000 m² E-commerce Warehouse

Client Background and Challenge

The client is a national e-commerce operator with an 8,000 m² warehouse and over 18,000 SKUs. Monthly sales growth reached 12–15%, with peak periods doubling operational load.

Manual sorting could no longer sustain volumes above 4,000 parcels per hour, resulting in:

• shipping delays

• congestion in sorting areas

• picking errors

• increasing labor costs

Project Objectives

• Achieve stable throughput of 6,000 parcels/hour

• Integrate with existing WMS

• Reduce manual labor

• Ensure system scalability

KONSORT Engineering Solution

A comprehensive conveyor-based warehouse automation system was implemented, covering:

• receiving

• barcode scanning

• automatic sorting (24 destinations)

• buffering

• packing

• dispatch

Technical Specifications

• Throughput: up to 6,000 parcels/hour

• Conveyor speed: up to 1.2 m/s

• Max unit weight: 30 kg

• Sorting accuracy: 99.4%

• Full WMS integration

• PLC-based control

Results

• +42% increase in processing speed

• -35% reduction in manual labor

• -60% decrease in picking errors

• stable peak-period performance

Return on Investment

Reduced labor costs and improved operational efficiency resulted in an estimated ROI of 18 months.

Client Testimonial

“KONSORT delivered not just conveyors, but a fully integrated warehouse automation solution. Our operations remain stable even during peak seasons.”