DFT has introduced a revolutionary modular Push Tray Sorter that transforms automated sorting by emphasising standardisation, flexibility, and speed. This innovative design aims to meet market demands for rapid deployment, cost efficiency and reliable performance in dynamic logistics environments. The core idea is to develop a product that can be quickly configured, installed, and maintained, reducing project lead times and operational risks.
Key Features of the Modular Approach
The system is based on standardised core components – primarily the electromechanical parts of the sorter track, infeeds and targets. These components are designed for mass production, ensuring economies of scale and consistent quality. In addition to this standardisation, customisation options are integrated to match different product ranges and specific application scenarios. This balance allows customers to tailor the sorter to their needs without sacrificing the benefits of modularity.
Minimising on-site labour is a primary goal. To achieve this, the modules are pre-assembled and feature plug-and-play wiring, significantly reducing installation time and complexity. This approach also facilitates future modifications or expansions, as system changes can be implemented with minimal disruption to ongoing operations.
Sales, Design and Implementation
The high degree of standardisation extends beyond manufacturing into the entire project lifecycle. Configurators enable the sales team to assemble solutions efficiently. This simplifies the design process and enhances communication with customers.
In addition, a CPQ (Configure Price Quote) tool automates the configuration, pricing and quotation process. By entering the customer’s requirements, reliable quotations are generated within a short space of time. This transparency speeds up decision-making, shortens the time from inquiry to contract and ensures that all relevant design data is available for a seamless transition to design and production.
Automated Engineering and Quality Assurance
In-house automation of engineering tasks enhances efficiency and quality. The system automatically generates wiring diagrams and PLC code and minimises manual engineering efforts. Standardised components can be stocked for quick assembly, reducing lead times and improving reliability. This approach ensures consistent quality and simplifies after-sales support.
Modular Software and Virtual Testing
A modular software strategy complements the hardware design. The software supports various operating modes tailored to the customer’s needs, with an open, industry-standard OpenAPI interface ensuring transparency and easy integration. A digital twin enables virtual testing of data exchange and host system integration prior to physical installation, reducing commissioning times and mitigating integration risks.
Advanced Monitoring and Service Options
DFT offers an integrated SCADA and analytics platform that provides real-time system visibility. Customers can access dashboards to monitor performance and identify potential problems at an early stage. The modular service portfolio includes hotline support, spare parts, maintenance visits and IT services. An e-service platform enables customers to carry out routine maintenance independently to ensure maximum system availability. Condition monitoring uses data analysis to proactively detect performance fluctuations or issues and optimise system performance.
Fast Deployment and Market Agility
The combination of standardisation, automation, and digital tools enables rapid project execution. Design lead times are compressed, and the risk of cost overruns or delays is reduced. Customers can react swiftly to market fluctuations, disruptions, or growth opportunities—whether deploying a new system or upgrading existing infrastructure.
Conclusion
The new modular design of the horizontal DFT Push Tray Sorter represents a significant advance for the automated sortation industry. It offers a scalable, customisable and cost-effective solution that supports fast deployment, high reliability and easy maintenance. By integrating digital twin technology, flexible software and comprehensive service options, DFT ensures that its customers are well equipped to meet the evolving needs of modern logistics and supply chain operations every time.
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