Sortation Systems in Houston, TX — Scan, Track & Divert Every Carton to the Right Destination
From low-rate divert gates to sliding shoe sorters running 200+ cases per minute, Lone Star Automated Systems designs, supplies, and installs complete sortation systems — induction, scanning, tracking controls, and diverts — for distribution centers across Texas.
Scan. Track. Divert. Repeat — Hundreds of Times a Minute.
A sortation system identifies each carton and sends it to its correct destination automatically. Automatic code readers scan bar codes and hand each carton off to a programmable controller, which uses pulses from an incremental encoder to track the carton down the line and fire the divert mechanism at exactly the right moment. Carton data can also be transmitted to your host computer for real-time visibility.
Sortation systems can use several methods to divert product depending on process requirements — sliding shoes, pop-up wheels, activated roller belts, or simple gates and pushers. The right choice comes down to your rate, carton mix, and gentleness requirements.
Upstream, live roller accumulation feeds the sorter, and skewed infeeds edge-align cases for reliable scanning. Downstream, takeaway lanes stage product for palletizing or shipping.
Four Ways to Divert — Matched to Your Rate
Sortation is a spectrum: the faster and more varied your carton flow, the more sophisticated the divert technology needs to be. We design and install across the full range.
Sliding Shoe Sorter
The high-rate sortation machine: shoes glide smoothly across continuous slats to push each carton onto its lane without impact. Available in single-sided or dual-sided configurations, the sorter consists of a drive section, intermediate sections with divert modules, an infeed tail section, and a slave-driven infeed load belt.
Performance: speeds to 600 FPM • peak rates above 200 cases per minute. Environment: 40°F (4°C) minimum ambient (mechanical limits) to 104°F (40°C) maximum (electrical limits).
High-Speed Pop-Up Wheel Sorter
In many applications, pop-up wheel sorters divert effectively: arrays of angled wheels rise between the carrying rollers at precisely the tracked moment, steering the carton onto its spur. Automatic code readers tie into the programmable controller for tracking, and carton data can be transmitted to your computer in ASCII format via RS-232.
Best for: medium-to-high rates where lane counts are moderate and carton bottoms are conveyable • pairs with brake spacer or brake meter belt induction.
Activated Roller Belt (ARB) Sorter
ARB technology embeds free-spinning rollers in the belt itself — activating them beneath the carton to align, rotate, merge, or divert without guards, pushers, or impact. One-size-fits-most handling makes it ideal for mixed case sizes and delicate packaging.
Typical range: widths 12"–36" • speeds 15–200 FPM • loads to 400 lbs • divert/merge, passive and selective 90° transfers, bump turning, and dual-lane rotation configurations.
Sorter Induction — Brake Spacer & Brake Meter Belts
Every sorter is only as good as its induction. A brake spacer belt provides defined head-to-head case separation based on carton length — adequate for consistent case sizes or a product mix with small length variations. A brake meter belt, with the necessary controls, provides a consistent gap between cartons and is the standard choice for inducting cartons with wider length ranges.
We size induction to: your carton size range, sortation rate requirement, and the divert technology downstream.
Simple Diverts for Simple Sorting Jobs
Not every operation needs a shoe sorter. For lower rates, mechanical diverts and flow-control devices sort, rotate, and meter product at a fraction of the cost.
Route product between lanes mechanically or on demand — the simplest sortation there is.
Pneumatic pushers sweep individual items off the line to a takeaway lane or reject station.
Rotate cases to the correct orientation for labeling, scanning, or palletizing.
Meter two converging lines into one lane without collisions at the merge point.
Match the Divert Technology to Your Rate
| Technology | Relative Rate | Best For | Key Notes |
|---|---|---|---|
| Gates, Pushers, Bump Turners | Low | Few lanes, low volumes, reject stations, orientation | Lowest cost; mechanical simplicity |
| ARB Sorter | Moderate | Mixed case sizes, gentle handling, merges and 90° transfers | Guarding-free; 15–200 FPM; loads to 400 lbs |
| Pop-Up Wheel Sorter | Medium–High | Case sortation to multiple lanes with scanner tracking | Encoder-tracked diverts; brake spacer/meter induction |
| Sliding Shoe Sorter | Highest | High-volume DCs and parcel operations | To 600 FPM; 200+ CPM; single or dual sided; 40°F–104°F ambient |
Sortation System FAQs
What is a conveyor sortation system?
A sortation system identifies cartons on a conveyor — usually by scanning a bar code — and automatically diverts each one to its correct destination lane, dock door, or packing area. A complete system combines an induction conveyor that creates gaps, a scanner and tracking controls, and a divert mechanism such as a sliding shoe, pop-up wheel, or activated roller belt.
How does a sliding shoe sorter work?
Cartons ride on continuous slats; at the divert point, shoes glide across the slats to push each carton onto its lane without impact. Shoe sorters run at speeds up to 600 FPM and sort at peak rates above 200 cases per minute, in single- or dual-sided configurations.
How do sortation systems track each carton?
An automatic code reader scans the bar code and hands the carton to a programmable controller. Using pulses from an incremental encoder, the controller tracks each carton's position in real time and fires the divert at exactly the right moment. Carton data can also be transmitted to your host computer.
What is carton induction, and why does gapping matter?
Induction is the metering conveyor ahead of the sorter that creates the gap every divert depends on. A brake spacer belt gives defined head-to-head separation based on carton length — fine for consistent case sizes. A brake meter belt with controls gives a consistent gap between cartons and is the standard for wider carton length ranges.
Which sorter type do I need for my rate?
Rule of thumb: gates, pushers, and bump turners for low rates; ARB sorters for moderate rates with gentle, guarding-free handling; pop-up wheel sorters for medium-to-high rates; and sliding shoe sorters for the highest rates — 200+ CPM at speeds to 600 FPM. We'll size the sorter to your current and projected volumes.
Does Lone Star Automated Systems install sortation systems in Houston?
Yes. We're headquartered in Houston, TX and provide layout, design, supply, installation, and controls integration for complete sortation systems — induction, scanning, tracking, diverts, and takeaway lanes — throughout Houston, the Gulf Coast, and all of Texas. Call 713-532-4444 for a quote.
Sortation System Design & Installation Across Texas
Lone Star Automated Systems is headquartered at 2500 Citywest Blvd., STE 150, Houston, TX 77042 and serves distribution centers, e-commerce fulfillment operations, parcel handlers, and manufacturers throughout the Gulf Coast and statewide.
Ready to Spec Your Sortation System?
Tell us your carton mix, lane count, and cases per minute — current and projected. We'll recommend the right divert technology, size the induction, and quote the complete system with controls.
713-532-4444
