Sortwyre connects to your existing sortation hardware via OPC-UA and continuously adapts induction and divert parameters to your current parcel mix.
vs. rated sorter capacity in validated deployments
continuous parameter updates without stopping the line
reduced from 8-15 per 10K on high-variability parcel days
operations, controls, and WMS integration specialists
Every parameter adjustment is visible, explained, and operates within the bounds your MHE vendor allows.
Continuously adjust parcel induction gap targets without stopping the line.
Sortwyre monitors scanner read-rate trends, divert confirmation latency, and downstream jam sensor activity to dynamically widen or narrow induction gaps during live operation. When scanner read rates drop below threshold—indicating label or parcel orientation issues—the system widens the induction gap to buy time for the divert decision without slowing the belt. Operators see the current rate target and its reason in the dashboard at all times.
Minimize mis-sorts by calibrating divert dwell time to actual parcel dimensions in real time.
Legacy sortation systems use fixed divert dwell times configured at commissioning and rarely updated. Sortwyre reads the dimensioner output for each parcel and calculates the minimum safe dwell time for that specific parcel’s footprint before the divert arm resets. For oversized or irregular parcels, dwell extends; for small envelopes, it shortens—pushing throughput higher on mixed-parcel days without the mis-sort spike fixed dwell times produce.
Surface belt and motor degradation signals before they cause unplanned downtime.
Sortwyre ingests motor current draw and belt tension readings alongside the standard PLC event log stream, flagging anomalous deviations 2–6 hours before failure events in validated deployments. Supervisors receive a push alert with the affected zone and a recommended inspection window so maintenance can intervene during a planned break, not during peak throughput.
Compare actual throughput against rated and historical shift performance without manual report assembly.
At shift end, Sortwyre generates a benchmark comparing actual parcels per hour against rated capacity, the prior 30-shift average, and the best comparable shift in the last 90 days. Breakdowns by zone and hour show exactly where shortfalls concentrated. Reports export to PDF and push to Manhattan WMS or SAP EWM automatically.
Alert the operations team when incoming parcel mix drifts outside the calibrated parameter range.
When the inbound parcel mix shifts significantly—for example, a sudden increase in large flat-rate boxes from a single shipper—Sortwyre detects the change within 15 minutes and alerts the supervisor with a recommended induction rate adjustment and the specific parameter change being applied automatically.
Post shift-level scan and sort confirmation data directly to Manhattan WMS or HighJump.
Sortwyre assembles a structured reconciliation record at shift close containing per-parcel scan confirmation, divert destination, and exception flags for reject-lane events. The record posts automatically to the operator’s WMS via Manhattan REST API or HighJump integration layer, eliminating the manual data-entry step that currently sits between sorter confirmation and WMS expected-sort reconciliation.
No cloud dependency for the real-time loop. Connect, baseline, optimize, report.
Direct connection to your sorter PLC via OPC-UA or Modbus TCP. No cloud relay required for the real-time optimization loop.
Sortwyre reads 30 days of PLC event logs to establish your facility's throughput baseline and current parameter configuration.
Every 90 seconds, updated induction rate and divert timing parameters are pushed back to the sorter PLC based on current parcel mix and equipment health signals.
Shift-level performance logs post to Sortwyre's dashboard and export automatically to Manhattan WMS or SAP EWM for operations review.
Recovery vs. rated sorter capacity in validated deployments at mid-size fulfillment centers with crossbelt sortation infrastructure.
The per-parcel re-handle cost range eliminated when mis-sort rates approach zero on high-variability parcel days.
The rolling window Sortwyre uses to calculate updated induction and divert parameters. No human intervention needed between cycles.
