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Pick-to-Tote vs. Pick-to-Belt

What Are the Methods of A-Frame Dispensing?

Pick-to-Tote vs. Pick-to-Belt

Our goal as the sole US provider of A-frames is to meet your order picking automation needs and ensure your system stays productive for years, with low operational costs, regardless of your chosen configuration. We offer two types of A-frame dispensing solutions: Pick-to-Tote and Pick-to-Belt. They both have distinct structural and performance differences that significantly impact their respective capabilities and effectiveness.

Workers replenishing order items in an A-Frame Dispenser System

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Pick-to-belt A-frame order picking system that ejects orders onto a cleated conveyor belt.

Pick-to-Belt

The Pick-to-Belt A-Frame dispenses order items onto a cleated conveyor belt at a maximum rate of 1,200 orders per hour.

The items are then transferred to a waiting tote at the end of the belt in a specific area known as the Transfer Zone before moving to the packing station.

Industrial conveyor system with blue plastic bins.

Pick-to-Tote

The SI exclusive Pick-to-Tote A-Frame dispenser picks at a maximum rate of 4,200 orders per hour and a 99.9% accuracy rate.

This system does not require a transfer zone, since orders are picked directly into totes, which are immediately routed to a packing station for shipping preparation.

A Frequently Encountered Misconception

Client: Having observed the Pick-to-Belt A-Frame in action at a particular warehouse, I am certain
that it is the optimal choice for my project because it is faster, cheaper, and easier to install.

Facts: While the pick-to-belt has been in use for several decades and is likely to be found in well-established warehouses, SI Systems has developed an updated version of the A-Frame known as the Pick-to-Tote that effectively addresses the various limitations of the PTB.

Let Us Examine This in More Detail:

Order Picking & Transfer Zone

The Pick-to-Belt system has a three-step pick process:

  • Orders are dispensed onto a moving cleated conveyor belt.
  • Dispensed orders are routed to a transfer zone at the end of the conveyor belt where they are deposited into waiting totes.
  • Totes are routed to a packing station for order verification and shipping preparation.

On the other hand, the SI exclusive Pick-to-Tote A-Frame has a two-step process.

  • Orders are dispensed straight into totes or cartons.
  • Totes are routed to a packing station. See an illustration of a three-tiered conveyor packing station.

Therefore, the pick-to-tote system simplifies the order-picking process by eliminating the transfer zone, resulting in a fully robotic pick process that is both faster and more cost-effective.

Speed & Accuracy

The Pick-to-Tote A-Frame can achieve picking speeds of up to 4,200 orders per hour due to the following reasons:

  • . It eliminates the repetitive tasks involved in the transfer zone.
  • It has a shorter indexing time.
  • The packing station processes are shorter due to the system’s unique pick accuracy of up to 99.9%.

The following factors contribute to the Pick-to-Belt’s limited pick rate of up to 1,200 orders per hour:

  • It inherently contains a lot of dead space due to longer indexing times.
  • . The transfer zone functions are labor-intensive and monotonous.

Accuracy

The pick-to-tote system employs sensors to ensure precise picking and includes an exception area for final verification of flagged and randomly selected orders.

On the other hand, the Pick-to-Belt lacks an exception area due to its intricate structure, causing a slower pack-out process as orders are verified within the system.

Archetecture, Conveyor & Drive

The Pick-to-Belt system's front end is more complex because of its intricate configurations, whereas the PTT's front end runs more smoothly due to its simple architecture.

Generally, designing and installing a Pick-to-Belt A-Frame costs more because of its custom flighted conveyors and drives, which call for more resources like labor, tools, and time.

On the other hand, the PTT uses readily available standard conveyors and drives and is easier to install and maintain.

Portability

The Pick-to-Tote has a portable, modular version that can be built over time as a warehouse grows.

Conversely, the architecture of the Pick-to-Belt cannot accommodate portability and therefore limits its use, especially in tight spaces.

Tote Sizes

For dependable tracking and accurate picking, it is essential that all totes, both in pick-to-belt and pick-to-tote systems, possess identical dimensions. Moreover, it becomes even more crucial to maintain consistent tote length as they determine the spacing of the A-frame's sensors.

Altering the dimensions of totes post-installation could necessitate significant modifications, potentially lifting the entire system or making other major structural changes.

Variability of Picking

The pick-to-belt and pick-to-tote systems maintain a steady order picking rate through regular flight intervals and consistent tote dimensions. This uniformity allows for efficient time management and planning.

Additionally, the conveyor belt speed can be adjusted to handle larger orders and ensure accurate picking.

Product Dimensions & Order Profile

With all their structural and performance differences, both pick-to-belt and pick-to-tote systems apply the same criteria for determining the application fit for order items and product dimensional requirements.

Click here to read more about the determining benchmark.

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SI Systems offers a comprehensive engineering and design study that assesses the most ideal pick technologies for order-picking projects. The study will analyze your SKU volume, SKU dimensions, and throughput requirement.

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