Case Study: Mid-Size Retailing Company achieves lower labor costs and greater fulfillment accuracy with Honeywell Intelligrated sweeper sorter

Sweeper Sorter Offers Cost-Effective Distribution Solution

A mid-size Retailing Company relocated to a larger facility and needed to improve fulfillment efficiency while handling growing throughput. Its legacy retail and direct-to-consumer operations relied on manual sortation for small, hard-to-sort items, creating extra touchpoints, labor-heavy processes, congestion risk, and a higher chance of picking and shipping errors. Honeywell Intelligrated helped the company address these challenges with a right-sized automation approach.

Honeywell Intelligrated implemented a two-stage sweeper sorter with wave picking to handle small packages in a minimal footprint. The solution reduced annual labor costs by 40%, cut staffing from 27 full-time employees to 16, shortened workdays from 14 hours to 8, and delivered a return on investment in less than two years. It also improved sorting accuracy, boosted customer satisfaction, and created enough capacity to handle order spikes.