Ferag Sorting Systems Conquer More and More Areas of Distribution Logistics

Highly efficient systems from the Swiss company Ferag AG for sorting, buffering, and distributing unit goods are increasingly found in various areas of distribution logistics. The spectrum ranges from fashion distribution to the food industry and e-commerce. Each system is designed around the product to be sorted and the individual sorting process to provide the customer with the optimal solution.

(Hinwil) The sorting and conveyor technology from Ferag is the result of the further development of processing lines originally designed for print media production, which incorporate over 60 years of experience as a technology leader. Despite their different construction and functionality, material flow systems like Denisort, Deniway, or Skyfall share a common foundation. All technologies – whether compact shell sorters, 3D plate chain conveyors, or pocket sorters – are highly modularized. The modular principle ensures that the systems offered by Ferag for distribution logistics can be easily scaled and adapted to changing needs over time without significant effort. This aspect proves to be a major advantage, especially for fast-paced industries like fashion or rapidly growing segments like e-commerce. At the same time, the systems from the Swiss material handling specialist impress with their high energy efficiency. For example, the Skyfall overhead conveyor can be designed so that individual carriers move solely by gravity over larger distances. The closely related Denisort, Deniway, and Easychain systems also operate with very few drive elements, which not only contributes to energy savings but also significantly reduces maintenance and operating costs.

Buffering and Sorting with Maximum Automation

One of the main domains of the Skyfall overhead conveyor has crystallized into order fulfillment for clothing and fashion items. The system can be used for both flat goods and “Garments on Hangers” (GOH). Its recipe for success is based on high throughput and extensive automation. For example, MAYORAL, a European market leader in children’s fashion, was able to significantly accelerate its distribution processes with the help of a massive Skyfall system, increasing output to 12,000 units per hour. The clever part: the lines can not only be automatically loaded and unloaded but also process the contents of hanging bags and hangers seamlessly in a colorful mix. With over 67,500 shuttle hangers for GOH, a primary buffer for 60,000 items, and a matrix sorter for 6,000 units per hour, the Skyfall system, which recently went into operation at PEERLESS CLOTHING in the USA, also sets new standards in fashion logistics.

Conveying and Sorting in a Continuous System

The tipping shell sorter Denisort has quickly earned a good reputation as an absolutely reliable sorting machine for different goods and packaging formats – both for classic shipping boxes and polybags. Depending on the application, the highly flexible, tiltable shell system allows throughputs of up to 12,000 units per hour. At the same time, the number of sorting destinations is virtually unlimited. It only depends on the available space for the discharge points or chutes. References such as sorting and allocating shoes (MYBOX), eyeglass lenses (ZEISS), or photo books (CEWE) demonstrate that Ferag engineers have optimized Denisort for gentle handling of products. Additionally, they have developed solutions specifically for the e-commerce segment to seamlessly connect the Denisort lines responsible for outbound sorting with upstream and downstream areas via AGV. Such a concept is currently being implemented at ZALANDO in Erfurt. Several Ferag systems are already in operation at this customer, including both Denisort and Deniway systems. The latter is used by the online retailer, among other things, for disposing of old cardboard packaging.

Optimal for Sorting in Second Packaging

The proven conveyor systems Deniway (up to 50 kg per running meter) and Easychain (up to 20 kg per running meter, tighter curve radii) are unbeatable in one respect: they form the most efficient interface between upstream production and palletizing currently available on the market. Therefore, they are primarily used in the production and distribution of food (NESTLE, GENNARI, FORNO BONOMI, BISLERI). Another application is the seamless material flow of healthcare products (ASTRA ZENECA, BEIERSDORF) between first and second packaging, where gentle handling, high quality, reliability, and ease of maintenance are required. It goes without saying that Ferag systems can also be combined with each other. For example, at the Finnish book wholesaler KIRJAVÄLITYS, the interaction between the Denisort line and the Deniway loop ensures optimized order fulfillment.
Photo: © Ferag