Versatile Applications Split Tray Sorter Simplifies Operational Complexity

The Split Tray Sorter, also known as the Bombay Sorter, is an innovative sorting system developed by RKSORT, specifically designed for the efficient processing of small to medium-sized items, particularly flat products. This sorter features an elliptical horizontal ring layout and is available in configurations with single or double-row trays. Items are placed in these trays and move along a circular track. When they reach their designated positions, the two halves of the trays open like doors, allowing items to drop vertically into chutes or material boxes, thereby completing the sorting action.

Thanks to its ability to load items on double-row trays simultaneously, the Split Tray Sorter can achieve impressive speeds of up to 21,600 trays per hour. It is especially effective for sorting clothing, express mail, printed materials, and other flat or non-fragile items, including those with irregular shapes. For additional information about the Split Tray Sorter, please consult the product description below or contact Realkey’s customer service team.

Technical Parameters

Product Features

Versatile Item Handling

The Split Tray Sorter is designed to transport items using trays, making it highly adaptable for sorting lightweight, floating, or irregularly shaped items not suitable for Cross Belt Sorters. It efficiently processes various packaging types, including boxes, plastic bags, cartons, and soft packaging.

High Efficiency with Low Speed

The unique "one cart, two trays" mechanism of the double-row Split Tray Sorter allows for sorting efficiencies that outperform comparable Cross Belt Sorters. Operating at a ring line speed of just 1.2m/s, it achieves sorting rates of up to 17,280 items per hour, with the potential for a dual-side feeding configuration to reach a theoretical maximum of 34,560 items per hour.

Exceptional Sorting Accuracy

Equipped with advanced intelligent cameras, the Split Tray Sorter can read codes from any angle, achieving a remarkable accuracy of up to 99%. High-tech sensors and PLCs quickly detect items and determine their paths, while the efficient tray handling mechanism ensures rapid and precise product separation, significantly minimizing error rates.

Flexible Design

By eliminating chain drives and wheel turning in its transmission system, the sorter utilizes distributed low-power motors placed at various points along the circular sorting path. This design allows for virtually unlimited sorter length and multiple destination paths, and its low-speed operation accommodates manual feeding without complex multi-level systems.

Compact Footprint

The innovative design of the Split Tray Sorter eliminates the need for additional multi-level feeding systems. Items can be sorted directly into bags or boxes, maximizing space efficiency. Its compact structure can be arranged around factory columns, minimizing overall space usage.

Energy Efficient and Low Maintenance

The sorter employs distributed low-power motor drives, leading to significant energy savings. Its mechanical unloading and resetting mechanisms are designed to minimize additional energy consumption beyond the main drive. The relatively low-speed operation reduces wear and tear, extending service life and lowering maintenance costs.

Modular Design

The entire machine features a modular design that supports rapid assembly, disassembly, expansion, and relocation, enhancing its versatility for various sorting applications.

Application

Split tray sorters are ideal for high-speed automated sorting of small and medium-sized items across various industries. They are commonly used in sectors such as footwear, books, e-commerce, postal services, daily essentials, pharmaceuticals, and jewelry. For very small or lightweight items that present challenges for other types of sorters, such as cross belt sorters, split tray sorters can effectively automate the sorting process.

These sorters excel in distribution centers serving consumers directly, facilitating batch picking and sorting of discrete orders, including e-commerce goods, retail clothing, omnichannel logistics, store replenishment, and returns processing. However, they are not suitable for fragile items that cannot withstand impacts; for such specialized sorting needs, the RKSORT-NBS series sorters from Realkey are recommended.

Advantages

V-shaped Tray Design

The unique V-shaped tray design accommodates easily rollable items, whether they are lightweight or irregularly shaped. If it fits in the tray, the Split Tray Sorter can manage it effectively.

Heavy-duty Tray Option

Our heavy-duty trays are built for demanding postal and courier environments, capable of supporting substantial loads, with each tray holding up to 15 kilograms.

Merging Tray Technology

The patented double-row tray design enables two groups of trays in the same row to sort different items to separate destinations, while also allowing for the merging of two trays to carry larger items during sorting.

Flat Stacking Technology

For folded garments, books, documents, and other flat items, products can drop directly into boxes or bags, typically eliminating the need for additional stacking labor.

Safety Design

The safety tray design ensures high sorting throughput even at lower speeds, with minimal gaps between trays. This design avoids sharp edges and reduces spacing between trays, ensuring operator safety.

Proven Reliability

With 17 years of experience in logistics and automated sorting solutions, Realkey has a strong reputation for delivering tailored sorting solutions. Our products are renowned for their durability and reliability, making us a trusted partner in the industry.