Product Overview

Light-directed Picking System (also widely known as Pick-to-Light system) is a high-accuracy, paperless order fulfillment technology designed for split-case and piece-picking warehouse operations. It installs digital LED light tags on each storage location of flow racks, shelving units and tote racks to visually guide operators to exact pick positions, required quantities and operation sequences.

Driven by a central control unit and seamlessly integrated with WMS/WCS platforms, it eliminates paper pick lists and manual SKU searching, drastically reduces picking errors and cuts down onboarding training time for new staff. It is ideal for high-SKU, low-volume order fulfillment scenarios, and can be flexibly combined with gravity conveyors, powered roller lines and sorting equipment to build a complete, efficient end-to-end picking workflow.

Main Types & Features

System Type	Core Feature	Typical Application
Pick-to-Light (Picking Mode)	Light tag mounted at each storage slot; indicator light + digital quantity display guides picking action; one-button confirmation after operation	Split-case piece picking, e-commerce order fulfillment, electronic component picking
Put-to-Light (Sorting Mode)	Light tags assigned to individual order slots; guides operators to sort bulk stock into corresponding orders by quantity	Wave order sorting, batch e-commerce fulfillment, cross-dock distribution
Zone-based Light Picking	Divides picking area into independent working zones; orders are automatically routed across zones; supports parallel operation by multiple operators	Large-scale distribution centers, high-volume order warehouses, multi-SKU picking zones
Flow Rack Integrated Light Picking	Pre-integrated with carton flow racks; combines FIFO gravity storage and light-guided picking; separate replenishment side and picking side	Fast-moving consumer goods picking, pharmaceutical storage, high-turnover SKU warehouses
Cold Storage Light Picking	Low-temperature resistant tags and sealed wiring; anti-fog digital display; stable performance under freezing conditions	Cold chain food picking, frozen product warehouses, pharmaceutical cold storage

General Technical Specifications

Item	Parameter Range	Notes
Picking Accuracy Rate	≥ 99.9%	Significantly higher than paper-based manual picking
System Response Latency	≤ 100 ms	Real-time order data synchronization
Light Tag Display	3-digit / 5-digit LED digital screen + status indicator light	Red / green / yellow indicator options available
Communication Protocol	RS485 bus / Ethernet / Wireless LoRa	Wired configuration recommended for maximum stability
Single Controller Capacity	64 ~ 512 tags	Expandable via controller cascading
Power Supply	DC 12V / 24V centralized power supply	Low-voltage design ensures operator safety
Protection Rating	IP54 (standard tags); IP65 (cold storage version)	Dust-proof and splash-resistant
Operating Temperature	0℃ ~ +50℃ (standard); -30℃ ~ +50℃ (cold storage type)	Special-grade components for low-temperature environments
Installation Method	Snap-on / screw mounting	Compatible with most standard rack profiles
Efficiency Lift	30% ~ 60% higher than manual paper picking	Varies with SKU complexity and order volume

Core Advantages

Industry-leading picking accuracy of ≥99.9%, effectively eliminates wrong picks, missing picks and quantity deviations, and reduces reverse logistics costs caused by order errors
Fully paperless operation eliminates the printing and distribution of pick lists, cuts paper consumption and avoids document loss or on-site confusion
Extremely short learning curve; new operators can be fully operational after 30 minutes of training, with no need for long-term SKU location memorization
Modular distributed structure allows flexible expansion of tag quantity and picking zones, supporting rapid on-site deployment and later system upgrade
Seamless integration with WMS, WCS and conveyor systems, realizing real-time order data synchronization and automatic task distribution
Optimizes picking routes, cuts down invalid walking of operators, and improves per capita picking efficiency by 30% to 60%
Supports full operation data statistics, including individual picking output, error rate and operation duration, facilitating warehouse performance management
Compatible with various rack types such as carton flow racks, shelving units and mezzanine floors, and supports multiple picking strategies including wave picking and zone picking

Typical Application Scenarios

01/

E-commerce Fulfillment Centers: Pick-to-light systems are widely deployed in split-case picking areas for multi-SKU small-parcel orders. Combined with carton flow racks and gravity conveyors, they enable fast processing of massive small orders, effectively handle order surges during promotional events, and significantly reduce shipping error rates.

02/

Pharmaceutical & Medical Device Warehouses: Light-directed picking complies with GSP management requirements, supports batch and expiry date management of pharmaceutical products, and eliminates manual picking errors. Paperless operation reduces cross-contamination risks, and full-traceability operation records ensure drug distribution safety.

03/

3C Electronics & Component Warehouses: For large quantities of small-sized, high-value electronic components and spare parts, the light picking system delivers precise quantity-based picking, prevents material mixing and wrong selection, and fits the refined management needs of massive SKUs in the electronics industry.

04/

Fast Moving Consumer Goods Distribution Centers: Put-to-light systems are applied to wave order sorting for cosmetics, daily chemicals and food products. Bulk stock is quickly distributed into each order slot according to order requirements, greatly improving batch sorting efficiency and shortening order fulfillment cycles.

05/

Automotive Spare Parts Warehouses: Zone-based light picking systems support classified picking of massive auto parts SKUs. Parallel multi-person zone operation improves overall picking efficiency, and accurate quantity indication eliminates missing-part issues in after-sales distribution.

06/

Cold Chain & Frozen Food Warehouses: Low-temperature resistant light picking systems operate stably in cold storage environments, reducing staff exposure time to low temperatures. The efficient picking mode improves frozen goods turnover efficiency and maintains product cold chain integrity.