For decades, the "Apparel DC" and the "Parcel Hub" lived in different worlds. Apparel facilities were the surgeons of the supply chain— requiring precision-handling of delicate fabrics, tiny polybags, and items on hangers. Parcel hubs, by contrast, were the heavy lifters, built to move rigid boxes at high throughputs.
But the lines have blurred. Thanks to the explosion of e-commerce and a need to reduce package sizing and weights, parcel networks now look remarkably like apparel DCs. If you walk through a modern carrier hub today, you aren’t just seeing boxes; you’re seeing a sea of flimsy polybags, lightweight mailers, and irregular "un-sortables."
The industry is learning a hard lesson: Speed is useless if the item doesn't stay on the sorter.
The New Reality: Small, Light, and Lethal (to Efficiency)
When your inventory shifts from heavy boxes to lightweight polybags, the physics of automation changes. Parcel networks are currently grappling with three specific "Apparel-style" challenges:
- Polybag Problems: Unlike cardboard, polybags have high friction, inconsistent shapes, and a tendency to "sail" or catch air at high speeds.
- Weight Irregularity: A 4-ounce t-shirt in a plastic bag doesn't have the gravitational "stick" of a 10lb toaster. On a standard belt sorter, these items can shift, slide, or even bounce off the system during turns or transitions.
- Speed Issues: In the old world, you increased throughput by increasing the sorter speed. In the new world, higher speeds often lead to more mis-sorts, and lost items.
The EuroSort Edge: Born in the Fitting Room
While many automation companies are currently scrambling to "ruggedize" their systems for parcels or "shrink" them for polybags, EuroSort has been living in this high-complexity space since day one. Our heritage isn't in large, heavy freight; it’s in the high-speed, high-accuracy world of garment handling, small parcel, and unit-level sortation.
We didn’t have to learn how to handle difficult items—we designed our systems specifically for them.
Why Tray Design is the Secret Weapon
Most sorters struggle with unstable items because they rely on friction to keep the item in place. EuroSort utilizes a pocket philosophy that physically contains the item.
- Total Control: By using a recessed tray design, we contain the items within the carrier regardless of shape or material
- Low Speeds: By reducing the space between trays and running the sorters slower, we eliminate the opportunity for lightweight mailers to blow off the sorter without reducing throughput.
- Positive Push Discharge: Our discharge mechanism has a physical push that ensures items go where they are supposed to. This means that whether it’s a 2oz jewelry mailer or a 30lb box, it sorts exactly where it’s supposed to.
Cross-Industry Wisdom
Because we’ve spent years in the trenches of global fashion retail, we’ve already solved the problems that many parcel carriers are now encountering. We understand that a "successful" sort isn't measured by how fast the motor turns, but by how few items require a human to go pick them up off the floor.
As distribution centers continue to converge, the winners won't be those with the fastest belts, but those with the most intelligent handling. We’re taking the precision of the apparel world and scaling it for the demands of the parcel industry.
After all, a parcel is just an apparel item that hasn't been opened yet.
