• Skip to main content
  • Skip to footer
  • (920) 499-5181
  • Locations
  • Online Catalog
  • 0 items in quote

    No products in the Quote Basket.

  • Equipment
    • New & Used Forklifts
    • New & Used Aerial Lifts
    • New & Used Industrial Cleaning Equipment
    • New & Used Utility Vehicles
    • New & Used Forklift Attachments
    • Forklift Accessories
    • Current Promotions
  • Services
    • Equipment Repair
    • Equipment Rentals
    • Equipment Parts
    • Safety Training
  • Systems
    • Warehouse Design & Layout Consulting
    • Storage & Pallet Racking
    • Warehouse Automation
    • Conveyor & Sortation
    • E-Commerce/Order Fulfillment
  • Insights
    • Forklifts
    • Aerial Lifts
    • Industrial Cleaning Equipment
    • Utility Vehicles
    • Systems
  • About Us
    • Careers at Conger
    • Our Friend Gusto

Conger Industries Inc. - Wisconsin's Material Handling Experts

We help businesses move material at peak efficiency with the right equipment & solutions

You are here: Home / Systems / Conveyor & Sortation / Sortation Conveyors
Sortation Conveyors
opex automated sortation scanning tunnel
tompkins robotic sortation with tilt tray
parts town distribution center shoe sorter conveyor sortation

Sortation Conveyors

With many sortation conveyors available, including traditional, robotic, merges and combiners, and automated case flow, we can help you:

  • Improve warehouse flow, productivity, efficiency, and reliability
  • Boost shipping accuracy, throughput, and inventory control
  • Accommodate a wide variety of products and processes
  • Handle expansion with highly-scalable, modular designs

 

Request a Quote

Documents

Product Documents

  • Conger Material Handling Systems Brochure

Case Studies

  • DICK'S Sporting Goods
  • Puma
  • Adore Me
  • Description
  • How It Works
  • Benefits
  • Types of Sorters
  • Applications
  • FAQs
  • Why Conger?

Improve Warehouse Flow, Productivity, Efficiency, and Reliability with Our Sortation Conveyor Systems

Do you need a material handling system that can help you:

  • Sift, separate, or arrange different products before sending them to other downstream processes?
  • Handle high product quantity flows?
  • Adapt to your floor plans, product specifications, and anticipate growth?

With Conger’s expert guidance, we can design a sortation system to help you with all those needs and much more!

How Sortation Conveyors Work

Sortation conveyors help bridge the gap between production process and reduce the need for manual labor by automatically sifting, categorizing, separating, dividing, inducting, or arranging products from in-feed conveyor lines. They are often used in high product quantity flow operations where items must be sorted before moving to other processes or destinations.

Sortation systems can identify products – whether individual pieces or cartons – and transport them to the appropriate destination within a facility.
Destinations often include downstream processes like storage, palletizing operations, packing stations, order fulfillment, pack out, or shipping lanes.

With a variety of options available, sortation systems can be as simple or complex as you need. Our automation experts will perform a system analysis to determine the most appropriate technology for your needs, taking into consideration your:

  • Facility floor plan and physical constraints
  • Product specifications, including type, size, and weight
  • Upstream and downstream activities, order fulfillment, pre-packing, routing complexity, and any automated equipment
  • Speed of product flow, number of merged lanes and infeed lines, desired throughput, and any special product handling needs
  • Any in-line equipment needs, such as ID and weight scanners or print and apply applicators
  • Anticipated year over year growth

The Benefits of Sortation Conveyor Systems

By leveraging Conger’s sortation conveyor design and implementation services, you can:

Improve warehouse flow, productivity, efficiency, and reliability

Harness an effective way to organize and route products before reaching downstream processes while also reducing the need to manually load, transport, and sort the products.

Boost shipping accuracy, production throughput, and inventory control

Integrate sortation systems with warehouse execution system software, larger order fulfillment systems, or technologies like goods-to-person systems to track products, control rates, analyze the most efficient routes, and provide greater overall visibility, more satisfied customers, and lower return rates.

Low capital cost expenditures and fewer operating expenses

We offer cost-effective sortation systems that can be implemented quickly for less reliance on manual labor along with a faster return on investment.

Versatile for a wide range of product and parcel types

Handle nearly any product types, sizes, and weights including sorting individual pieces or cartons, and with the ability to operate in minimal space.

Easy to reconfigure or expand

Highly-scalable, modular sortation designs can accommodate increased SKU volume, growing demand, diverts for kitting or new processes, or in-line scanners for additional QA/QC considerations.

Types of Sortation Conveyors

We offer various sortation system designs, depending on the specifics of your items, product flows, and other needs. These include:

Traditional conveyor sortation

  • Traditional conveyor sorters arrange products from multiple infeed lines for greater efficiencies in distribution operations
  • They help to seamlessly maintain product flow for further sorting, scanning, or fulfillment processes
  • Various conveyor technologies are available designed for versatility to accommodate different product types, facility layouts, and processing requirements

Robotic sortation

  • Robotic sortation is a high-speed and flexible low entry point alternative to traditional conveyor sorters
  • These systems provide an effective sortation method for handling multi-line E-commerce orders, parcel sorting, and reverse logistics
  • Many robotic systems are available, including the Tompkins Robotics T-Sort System, the world’s first portable automated sortation system, and the OPEX® Sure Sort, which is designed for small items and parcels of any shape weighing up to 5 pounds

Merge and combine sortation

  • Applicable across many industries, merge and combine systems arrange products flowing from multiple conveyor infeed lines while providing smooth, automated transitions to reduce damage
  • Merge sorters arrange and consolidate products from multiple upstream pick modules and conveyor infeed lines into a single stream of products downstream for further processing, often into a sorter, in-line scale, or scanner
  • Combiner sortation is when conveyor lines are fed into a single wide merge area that serves as a funnel before traveling to the narrower, merge takeaway conveyor

Automated case flow conveyors

  • Designed for automatically building small and large mixed pallets, such as for beverage orders
  • Maximum throughput of 2,500—4,000 cases/hour with the ability to handle over 500 unique SKUs
  • Case flow conveyors help reduce labor costs, increase the speed of building mixed pallets, help reduce labor and injuries, and improve warehouse space utilization

Custom sortation systems


Conger takes a brand-agnostic approach to sortation conveyor design, which means we use whatever products are best for your project. This makes it easier to tailor the solution to the needs of your business. We will work with you to design and implement turnkey or custom options based on your:

  • Product size, weight, durability, and mix
  • Throughput rate requirements for downstream processes
  • The expected density of product accumulation

Common Sortation Conveyor Applications

  • Distribution centers
  • Micro-fulfillment centers
  • Small businesses looking for a cost-effective entry into fulfillment automation
  • Larger fulfillment operations looking to streamline processes

Frequently Asked Questions About Sortation Conveyors

Do you have questions about sortation conveyors? We have answers.

I handle lots of different types of products in my operation. Can you design a sortation system that accommodates each of them?

Yes! We offer sortation systems that can fit nearly any product size, shape, and weight. Our experts will consider your product specifications and flows when selecting existing systems or creating custom systems to ensure they fit your handling needs.

I have a small operation. Do I have the budget for a sortation conveyor system?

We work with large and small firms alike and will take into account any budgetary issues to ensure we find the best solutions that won’t break the bank and will deliver the best return on investment.

I have multiple processes involved in my operation. Will a sortation system be able to handle the needs of each?

Our experts will consider your operation holistically, including aspects such as picking/packing, shipping, facility layout, and production rates to create a sortation system that takes into account each moving part of your operation.

Why Choose Conger for Your Sortation Conveyor Needs?

With over 65 years in the material handling industry, we have the experience and expertise to design and implement sortation systems, regardless of your facility, operations, and products handled.

Our experts, in coordination with equipment specialists, will find the right combination of sorters, conveyors, and/or ancillary equipment to improve your efficiency and productivity while minimizing costs.

Footer

Get In Touch With Us

Feel free to contact us the old fashioned way. Sometimes it’s nice to talk to a real person.
_
t: (920) 499-5181

  • Facebook
  • LinkedIn
  • YouTube

Copyright © 2025 · Conger Industries Inc. · Green Bay, WI · Neenah, WI · Wausau, WI · Richfield, WI · Madison, WI.

Sales Terms & Conditions · Rental Terms & Conditions · Service Terms & Conditions