Case Study: HOJ Engineering achieves scalable, space-saving e-commerce fulfillment and a 33% peak-capacity boost with Honeywell Intelligrated vertical sortation

Vertical Sortation Drives Efficient E-Commerce Fulfillment

HOJ Engineering faced an online-retailer fulfillment challenge: rapidly rising order volumes, frequent peak surges, and the need for continuous replenishment and simplified storage/slotting across thousands of suppliers and 350,000 SKUs. The solution had to be flexible, scalable and space-efficient while reducing handling and labor.

Honeywell Intelligrated USS installed 10 high-speed vertical conveyors integrated with horizontal sortation to create 60 delivery locations and 120 pick zones, using direct-to-zone and zone-to-zone tote routing that keeps pick lanes clear. The system handles 50,000 orders per day with an extra 33% peak capacity, eliminates slotting constraints (store any product anywhere), improves labor utilization and reduces product damage while remaining easily expandable for growth.

HOJ Engineering