Revolutionizing Warehouse Efficiency Unleashing the Power of ModSort
Efficiency is the driving force behind successful distribution warehouses. For decades, the distribution industry relied on manual sorting procedures. But when package types change and business grows quickly, manual sortation can slow things down and drive up costs.
One North Carolina warehouse faced this exact challenge. Their team was spending too much time and money manually sorting packages. That’s when they turned to the ModSort® Divert and Transfer Module. This smart solution improved operations and saved thousands of dollars a year in labor costs.
Why Traditional Sorting Methods Fall Short
Over the last decade, packaging has seen a dramatic change. Instead of boxes, warehouses are shipping more items in polybags. Varying package types, along with the rise in ecommerce means the distribution industry is keeping busy. When warehouses deal with shifting package types, the demand for timely sorting skyrockets. Warehouses face a dual challenge: adapting to new package types while ensuring seamless operations.
The traditional approach is using totes to convey polybags. But this increases manual labor and sorting time, leading to mounting labor costs. Management needs a solution that streamlines operations, boosts conveyor speeds, and reduces manual handling. For a distribution facility in North Carolina, workers faced this exact challenge.
This warehouse handled a mix of boxes and polybags. Sorting polybags using totes added extra steps and slowed down the process. Workers spent 80 hours a week pulling totes by hand. This cost the company $21.50 per hour in labor.
That added up to $90,000 a year in labor costs.
How ModSort Transformed Operations
After installing the ModSort module, the warehouse saw immediate improvements:
- No more totes: The system eliminated the need for manual tote handling.
- Run-on-demand technology: It only runs when needed, saving energy.
- Zero-contact, zero-pressure accumulation: Packages move smoothly without damage or delays.
This upgrade allowed workers to focus on more valuable tasks, improving overall productivity.
ModSort Means Faster, Cleaner, Smarter Sorting
Savings $90,000 per year wasn't the only benefit of switching to ModSort. Here’s what else the warehouse gained:
- Faster conveyor speeds: Increased from 50 ft/min to 90 ft/min.
- Better handling of polybags: Thanks to the System Plast® 2253 Roller Top belt, packages move without gaps or jams.
- Energy savings: The 24VDC system uses 50–60% less energy than traditional conveyors.
- Low noise operation: Creates a quieter work environment.
- Simplified maintenance: Fewer spare parts and better package control reduce downtime.
Future-Proof Your Warehouse with ModSort
ModSort isn’t just a tool. It is a smart investment. ModSort can help warehouses adapt to changing demands, reduce costs, and stay competitive. With automation and intelligent design, facilities can work faster, safer, and more sustainably.
Ready to improve efficiency and cut labor costs? Talk to our team about integrating ModSort into your facility.