Case Study: USPS National Distribution Center achieves 10,000 parcels/hour throughput and major shipping & labor cost savings with Invata Intralogistics

USPS National Distribution Center - Customer Case Study

USPS National Distribution Center faced rising parcel volumes that exceeded the throughput and capacity of an existing zone‑skipping sortation line, which required manual handling and manual scans and was limited to 4,000 parcels per hour—driving up per‑unit labor and shipping costs. Invata Intralogisitcs was engaged to re‑engineer and expand the zone‑skipping processing and sortation system, leveraging its FastTrak® Warehouse Control System and automated material‑handling solutions.

Invata Intralogisitcs implemented compact high‑throughput conveyors (including a vertical elevator/lowerator), semi‑automated induction, a singulation/scan tunnel tied to FastTrak®, and a second 6,000 pph small‑parcel sorter, fully integrating with the existing WMS and TMS. The solution raised capacity from 4,000 to 10,000 parcels per hour, eliminated many manual touches and manual order scans, enabled weight checks and exception routing, expanded parcels eligible for zone skipping, and delivered lower labor and shipping costs per unit with a quick payback.