The second sort step is the real bottleneck
Batch picking speeds up collecting, but it shifts the work to sorting. Every product picked in a batch still has to be split back out per order, and that is where things stall.
Manual re-sorting is slow
Staff split picked batches across orders by hand. That takes time, ties up pack tables and throttles throughput during peaks.
Error-prone under pressure
The faster the pace, the higher the chance a product ends up in the wrong order. Mispicks drive returns, complaints and rework.
Labor-intensive and hard to scale
More orders means more sorting hands. With growing volumes and a tight labor market that is barely sustainable.
The MicroSorter as a batchpick sorter
The MicroSorter takes over the sort step after batch picking completely. Every product is scanned and automatically sorted to the right order. What competitors call 'batch pick and sort' or 'batch pick 'n scan', the MicroSorter does compactly, fast and accurately.
- Every product scanned and sorted to the right order
- Up to 1500 products per hour with 99.9% accuracy
- 40+ order destinations in one compact setup
- Direct integration with your WMS or WCS
What is a batchpick sorter?
A batchpick sorter is an automated sorting system that splits batch-picked products back out into individual orders. In batch picking, an operator or robot collects products for multiple orders in a single pick tour. That saves a huge amount of walking, but it produces a mixed tote that is not yet separated per order. The batchpick sorter takes it from there. Every product is scanned individually and sorted to the right destination based on its order number. From a single batch you automatically get a series of complete, verified orders, ready for packing and shipping. The Collo-X MicroSorter is exactly that kind of batchpick sorting system. Its compact, modular design fits into existing warehouses and processes up to 1500 products per hour to more than 40 order destinations, with a sorting accuracy of 99.9%.
Batch picking versus single-order picking
With single-order picking an operator walks the warehouse per order. Simple, but with many small orders it creates a huge amount of walking: a large share of pick time is spent just moving around. Batch picking turns this around. Products for ten, twenty or more orders are collected in one tour. Walking distance per order drops sharply and pick speed shoots up. The flip side: at the end of the tour everything is mixed together and still has to be sorted per order. That sort step is exactly where a batchpick sorter makes the difference. Without automation, the gains from batch picking evaporate into manual re-sorting. With a batchpick sorter like the MicroSorter, the speed gain is preserved and sorting becomes the fastest and most reliable step in the process.
When does automatic sorting after batch picking pay off?
Automatic sorting after batch picking pays off as soon as volume and the number of order lines structurally increase. Rule of thumb: from a few thousand order lines per day, or as soon as manual re-sorting becomes a fixed bottleneck in the peak, a batchpick sorter pays back quickly. The business case rests on three items. First, labor: the MicroSorter replaces manual re-sorting and quickly saves up to 60% on sorting labor. Second, quality: at 99.9% accuracy, mispicks, returns and correction costs go down. Third, lead time: orders are complete sooner, enabling later cut-off times and faster shipping. Want to know what a batchpick sorter delivers in your situation? Request a demo or a no-obligation capacity and ROI calculation. We work through together what automatic sorting after batch picking means for your volume.
Specifications
Built for sorting after batch picking
Benefits of a batchpick sorter
Why the MicroSorter for sorting after batch picking?
Up to 1500 products/hour
Keep the speed gain of batch picking in the sort step.
99.9% accuracy
Every product scanned and verified to the right order, with fewer mispicks.
Up to 60% less sorting labor
Replace manual re-sorting and deploy people on more valuable work.
Scales with your volume
Modular design with 40+ order destinations, easy to expand.
Connects to your WMS/WCS
Standard interfaces for seamless integration with your existing software.
Orders complete without walking
From a single batch you automatically get complete orders, ready to ship.
Frequently asked questions
Answers about the batchpick sorter and sorting after batch picking