Product Overview

Light-directed Sorting System, commonly referred to as Put-to-Light system, is a high-efficiency paperless sortation solution designed for batch order consolidation and wave picking scenarios. It deploys digital LED light modules at each order sorting slot, using illuminated indicators and digital quantity displays to guide operators to distribute bulk items into corresponding target orders accurately.

Controlled by a central management unit and fully integrated with WMS/WCS platforms, it eliminates manual order checking and paper sorting lists, drastically cuts sortation errors and reduces reliance on skilled operators. It is optimized for high-volume, multi-order sortation workflows, and can be flexibly paired with conveyor lines, flow racks and picking systems to build a complete end-to-end order fulfillment chain.

Main Types & Features

System Type	Core Feature	Typical Application
Standard Static Put-to-Light	Fixed sorting wall with dedicated order slots; batch items are distributed one by one; supports large-scale slot expansion	E-commerce wave order sorting, retail distribution center sortation
Mobile Light Sorting Cart	Integrated light tags on movable trolley; suitable for decentralized sorting and on-site order consolidation	Multi-zone warehouse sortation, cross-aisle order assembly, small-batch custom sorting
Zone-based Light Sorting	Divides sortation area into parallel zones; orders flow across zones automatically; supports multi-operator parallel operation	Large-scale distribution centers, high-volume e-commerce fulfillment hubs, bulk cross-dock sortation
Conveyor-integrated Light Sorting	Mounted alongside main conveyor lines; items are picked from belt and placed into lighted chutes directly	High-throughput sortation trunk lines, parcel distribution hubs, fast-moving consumer goods sorting
Cold Storage Light Sorting	Low-temperature resistant sealed light modules; anti-fog display; stable operation in freezing environments	Cold chain food sortation, frozen product distribution, pharmaceutical cold storage sorting

General Technical Specifications

Item	Parameter Range	Notes
Sorting Accuracy Rate	≥ 99.9%	Far outperforms manual paper-based sortation
System Response Latency	≤ 100 ms	Real-time wave order data synchronization
Light Module Display	3-digit / 5-digit LED screen + status indicator	Supports multi-color indication for different operation status
Communication Protocol	RS485 bus / Ethernet / Wireless LoRa	Wired configuration recommended for maximum stability
Single Controller Capacity	64 ~ 512 sorting slots	Expandable via controller cascading
Power Supply	DC 12V / 24V centralized power supply	Low-voltage design ensures on-site operational safety
Protection Rating	IP54 (standard modules); IP65 (cold storage version)	Dust-proof and splash-resistant
Operating Temperature	0℃ ~ +50℃ (standard); -30℃ ~ +50℃ (cold storage type)	Industrial-grade components for extreme environments
Installation Method	Snap-on / rack-mounted / wall-mounted	Compatible with standard racks, sorting walls and conveyor frames
Efficiency Improvement	40% ~ 70% higher than manual paper sorting	Varies with order volume and SKU complexity

Core Advantages

Sorting accuracy up to ≥99.9%, effectively eliminates wrong order placement and quantity mismatches, and reduces return costs caused by sortation errors
Fully paperless sortation workflow removes printing and distribution of sorting lists, cuts on-site document management costs and avoids order misplacement
Ultra-short operator onboarding cycle; new staff can master standard operations within 30 minutes, no long-term memory of order slots required
Optimized wave sortation logic greatly reduces unnecessary walking of operators, and improves per capita sortation throughput by 40% to 70%
Modular distributed architecture supports flexible expansion of sorting slots and operation zones, adapting to business growth and seasonal peak demand
Seamless integration with WMS, WCS and conveyor systems, realizing automatic wave order distribution and full-process data traceability
Supports multiple sortation strategies including single-item wave, multi-item wave and cross-dock sortation, matching different order structure characteristics
Complete operation data statistics, including per capita output, sortation error rate and order processing cycle, supporting fine warehouse performance management

Typical Application Scenarios

01/

E-commerce Wave Order Sorting: Light-directed sorting systems are widely used in e-commerce fulfillment centers for post-picking order consolidation. Bulk items picked by wave are distributed to each order slot accurately according to digital prompts, significantly improving the processing efficiency of multi-SKU small orders and coping with order surges during promotional periods.

02/

Retail & Supermarket Distribution Sortation: For chain store distribution, the system sorts bulk goods into corresponding store orders at one time, realizing fast batch distribution of fast-moving consumer goods, food and daily necessities, and shortening the delivery cycle from distribution center to offline stores.

03/

Cross-dock Distribution Hubs: Deployed at cross-dock logistics hubs, the system directly sorts incoming bulk goods to target delivery routes without storage links. It improves cargo turnover efficiency, reduces warehouse storage pressure and is suitable for fast-circulation FMCG and express distribution scenarios.

04/

Pharmaceutical & Medical Device Distribution: Complying with GSP management specifications, the system supports batch and expiry date traceability during sortation. Paperless operation reduces cross-contamination risks, and accurate quantity control ensures safe distribution of pharmaceutical and medical products.

05/

Apparel & Footwear Order Sortation: For multi-SKU, multi-size apparel orders, the light-directed sorting system realizes fast order consolidation of different styles and sizes. It avoids mixed-size and mixed-style errors, and fits the characteristics of seasonal high turnover in the apparel industry.

06/

Cold Chain Food Distribution: Low-temperature resistant light sorting modules operate stably in cold storage environments, reducing staff exposure time in low temperatures. The efficient sortation mode maintains cold chain integrity and improves the turnover efficiency of frozen and refrigerated food.