Order Consolidation in Fulfillment Operations
Order consolidation is a fulfillment strategy that combines batch picking with automated or manual sorting, enabling multiple orders to be processed efficiently from a single pick trip. After items are batch picked, they are routed to an order consolidation area, where inventory is sorted into the correct customer orders.
This approach is ideal for high-volume operations looking to increase productivity, reduce errors, and lower shipping costs.
Benefits of Order Consolidation
Increased Efficiency
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Consolidating orders downstream from batch picks streamlines the process and increases order throughput.
Improved Accuracy
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Technologies like light-directed put walls and robotic sortation ensure each item ends up in the right order, reducing manual errors.
Cost Savings
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Accurate shipments result in lower shipping costs and improved operational efficiency.
Types of Order Consolidation Technologies
Order consolidation can be powered by a range of item sorting technologies. Trew integrates and supports multiple options based on your operation’s size, SKU complexity, and fulfillment strategy:
Light-Directed Put Walls
Ideal for manual operations using visual cues to guide sorting (Trew) - Put wall solutions provide a flexible and scalable order consolidation for ecommerce and kitting operations. Inventory items are presented to an operator in donor totes, which were created by a batch picking process somewhere else in the building. After scanning an item, a put-to-light device indicates to the operator which order, put-wall cubby, the item is associated with. This method of order consolidation enables 450+ lines per hour throughput with +99% order accuracy.
Robotic Put Walls
Automated systems like OPEX Sure Sort - a compact scalable small-item sorting system alternative to traditional put wall that can be applied in order consolidation, retail replenishment, inbound SKU, kiting, returns and parcel sortation applications.
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Robotic Order Consolidation Systems
Advanced item handling using solutions like Berkshire Grey Stride™ Shuttle Sorter - an automated store replenishment fulfillment & sortation alternative to put walls and item loop sortation that can increase order fulfillment by up to 4X, maximize shipping container cube utilization by up to 10%, and fit in a compact footprint.
High-Speed Item Sorters
Scalable unit sorters like those from EuroSort for dense, high-throughput operations - Goods-to-sorter induction strategies supersize the Put Wall order consolidation process achieving sort rates of up to 9,600 items per hour, or 13,300 items per hour when virtual sortation configurations are used. The solution presents inventory to an operator who inducts the items on a loop sorter. The loop sorter sorts the item into an order chute for consolidation. Multiple configurations can be implemented for induction stations and order chutes to match the volume of operations and inventory types.
Finding the Right Fit
Every warehouse is different. At Trew, we help you choose the order consolidation technology that best fits your:
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Order volume
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SKU profile
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Facility footprint
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Fulfillment goals
Whether you’re working with an existing facility or starting from scratch, order consolidation technologies can deliver scalability, flexibility, and positive return on investments.
SureSort is a registered trademark of OPEX Corporation. All rights reserved. OPEX is one of Trew’s integration partners.
Core™ Robotic Picking System and Stride™ Shuttle Sorter is a trademark of Berkshire Grey. Berkshire Grey is one of Trew's integration partners.
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