High-Speed Cross-Belt Sorting. Built for Scale.
Automate parcel sorting with precision, speed, and intelligence.
✔ Handles cartons, apparel, parcels and printed items
✔ Proven solution for e-commerce and express logistics
✔ IoT-enabled for real-time control and optimisation
What is a Cross-Belt Sorter?
The Cross-belt Sorter consists of dozens or even hundreds of independent belt-conveyor carriers that move perpendicular to the main conveyor direction. The system includes infeeding (manual or automatic), spacing, parcel positioning, identification, the sorter host, outfeeding, and an integrated control system.
It efficiently sorts a wide range of items, including cartons, boxes, apparel parcels, printed materials, and other small to medium parcels. Due to its speed, accuracy, and flexibility, it has become the mainstream sorting solution for e-commerce, express logistics, footwear, apparel, and distribution centres.
Built on IoT-driven intelligence, the high-speed Cross-belt Sorter is more than just a sorting machine, it functions as an intelligent unit within a smart logistics ecosystem, enabling real-time data exchange, system optimisation, and scalable automation.
Functional Design Specification
The solution integrates a Cross-Belt Sorter, multiple induction lines, barcode scanning, dimensioning, check weighing, chute-based sortation, and a dispatch pallet handling system.
It operates as a fully automated material handling system controlled by PLC-based controls, a High-Level Control (HLC) system, and 3D SCADA software, interfacing directly with the Warehouse Management System (WMS).
Cross-Belt Sorter
Independent belt carriers move perpendicular to the main sorter direction
High-speed, accurate parcel discharge
Handles mixed parcel profiles including cartons, apparel, and soft packages
Supports dynamic chute reassignment (re-mapping)
Identification & Data Capture
5-sided barcode scanning
Inline dimensioning and check weighing
Parcel data tracked end-to-end through the system
High barcode read and data capture accuracy
Control & Intelligence
PLC-based low-level controls
High-Level Control (Freight Flow) for:
Sort logic and routing
Exception handling
Reporting and dashboards
3D SCADA (Sym3) for real-time visualisation, alarms, and diagnostics
Parcel Sortation
Throughput: up to 9,000 parcels per hour
System availability: 99.5%
Sort accuracy: 99.99%
Barcode read rate: ≥ 99.5%
Noise level: ≤ 75 dBA
Parcel Size Range
Length: 200–1500 mm
Width: 100–750 mm
Height: 15–800 mm
Weight: 0.25–30 kg
Zoned emergency stop system, Local control stop zones
Audible and visual pre-start warnings
Full compliance with Australian electrical and WHS standards
Guarding, access platforms, and safe maintenance design throughout
Siemens PLC-based control system
Distributed motor starters (VSD & DOL)
ASi-Bus for field device connectivity
Ethernet & Profinet networks
Redundant safety and fault monitoring
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