100+ installations worldwide: Trust through practice

With more than 20 years of experience in adapter technology, DFT now has an installed base of more than 100 adapter systems. The concept of overhead conveyor technology not only works under simple sorting requirements, but is also operated stably in very different e-commerce, store and multi-channel environments. In total, over 15 million adapters and more than 8 million EcoPockets as well as over 750,000 AutoPockets are in use. These figures not only stand for market penetration, but above all for a wealth of experience from real applications.

This range can be an investment argument for decision-makers. Each system provides installation and operating experience: from ramp-up phases and seasonal peaks to long-term system stability. This knowledge is incorporated into further development and makes performance data reliable. In addition, there is a sophisticated spare parts and maintenance concept, supplemented by a SCADA combined with in-depth analytics software.

The modular design allows extensions or step-by-step planned expansion. Additional routes, more sorting capacity or further feed stations and destinations can be systematically integrated. Because interfaces, components and service processes are standardized and used across all customers, expansions also remain calculable. This reduces project risks, facilitates investment approvals and ensures that performance and availability remain reproducible for years to come.

Hanging sorter as fulfillment backbone

In the modern distribution center, pocket or adapter sorting solutions take on central tasks along the order chain. They enable pre-picks (pre-picking, where items are picked in advance and later assigned to specific orders to reduce throughput times) and batch processing (simultaneous processing of several orders in a joint process to increase efficiency and throughput), consolidate items from different storage areas, simultaneously process different channels (B2B/B2C, store/end customer) and support efficient returns handling. They demonstrate their particular strengths in structurally complex locations: When flows of goods need to be moved quickly, safely and with minimal errors between levels and zones, overhead conveyors enable flexible material flow design.

This also highlights the role of technology. Hanging sorters are not an add-on, but an infrastructure component that connects areas and sets the pace. This is precisely where the strategic benefit lies: Processes become more robust in the face of volume fluctuations because sorting does not depend on staff availability, but on reproducible system performance.

The new material flow cycle: 12,000/h per module

The demands placed on modern distribution centers are developing faster than many facilities can grow. Growing order volumes, volatile peaks, rising return rates and an increasingly tight labor market are putting fulfillment processes under pressure. Short delivery times demand material flow solutions that can also reliably deliver their performance in day-to-day operations. While many companies are considering structural extensions or complex automation solutions, one technological development is proving to be particularly effective: high-performance overhead sortation systems that combine speed, stability and scalability in a single material flow concept.

DFT has helped shape this development over the past 20 years. With the current generation of adapter solutions, the company is providing a new level of performance. The systems achieve a usable sorting capacity of up to 12,000 adapters/h per module - a benchmark that clearly demonstrates how quickly and flexibly modern overhead conveyor technology can operate today. The power density of this technology allows fulfillment processes to be accelerated.

Business impact: speed, efficiency, process reliability

The combination of 12,000-cph output and proven adapter technology results in measurable benefits: faster order processing, sorting, consolidation and channel processing come together in a stable process flow. At the same time, capex and opex are reduced when the same performance is achieved with fewer modules and proven standard components simplify service and spare parts. Returns handling also benefits because returns can be integrated into the same cycle and transferred cleanly to downstream processes, allowing them to be quickly fed into the sales process.

Proven and ready for further growth

"Proven 100 Times" describes the fact that the technology is used in a large number of real installations and has proven itself over a long period of time. More than 100 installed adapter systems, millions of adapter and pocket systems in use and the new 12,000 capacity show how hanging sortation systems are becoming a strategic fulfillment infrastructure.

About Dürkopp Fördertechnik

The company with 500+ employees first became known in 1954 as a division of Dürkoppwerke in Bielefeld. After being spun off as a separate limited company (1995), it has been part of the Austrian Knapp AG, based in Graz, Austria, since 2010. DFT develops, produces and integrates sorting and sequencing systems for the efficient processing of e-commerce orders, store supply and returns management. DFT operates worldwide, with a current focus on Europe and North and South America. DFT develops overhead and horizontal conveyor technology for apparel logistics, electronics and wholesale, pharmaceutical wholesale and for applications in the general e-commerce environment.