Case Study: United States Postal Service achieves 30% faster tray handling and 200 pieces/min sortation with Bastian Solutions

United States Postal Service - Customer Case Study

The United States Postal Service needed a fast, space-efficient way to automate tray sortation at its Indianapolis General Mail Facility without interrupting 24/7 operations. Bastian Solutions was engaged to address challenges including reading sleeve labels at 550 feet/minute while mail shifted inside trays, handling tray weights up to 75 lbs, sorting to 235 ZIP-code ranges at a target 135 pieces per minute, and processing nearly 150,000 trays (~300 trucks) within a 160,000 sq. ft. footprint. Bastian Solutions proposed a mechanized two-floor tray handling system using technologies such as the Intelligrated Sort Touch One-Way Shoe Sorter, AccuSort AV400 camera scanner paired with an Axiom line scanner, zero-pressure accumulation conveyors, induction lanes, Anchor mezzanine, OCS scales, and Intelligrated controls.

Bastian Solutions installed the system and employed a two-pass sortation methodology to meet ZIP-code coverage and capacity goals; the solution eliminated manual cart handling and maximized floor space. Results exceeded targets: peak sort rates reached 200 pieces per minute (vs. 135 target), USPS saw a 30% reduction in tray handling time, and commissioning finished two weeks early. Bastian Solutions completed the project safely and efficiently without disrupting continuous mail processing.

United States Postal Service