High-Speed Garment Drop Tray Sorting System Solution by Gosunm
Recently, Gosunm successfully completed and shipped a customized Bomb bay sorting production line. This system is specifically designed for garment logistics and distribution centers, capable of directly sorting unpackaged clothing products, ranging from lightweight garments to outerwear. This fully demonstrates Gosunm's system integration capabilities and customized R&D strength in the field of logistics sorting automation.
Client Background
The Israeli end-user is a regional logistics and distribution service provider for the apparel industry, primarily serving the clothing, e-commerce, and retail supply chain sectors.
With the expansion of their business and the rapid increase in the number of SKUs, traditional manual sorting methods could no longer meet their requirements for efficiency, accuracy, and operational stability.
The client hoped to achieve the following through an automated sorting system:
- Direct sorting of unpackaged garments
- Intelligent diversion integrated with an RFID system
- High-density sorting chute configuration
- Long-term stable operation
- Compliance with local electrical and safety standards
Drop tray sorting system Project Challenges
In this project, Gosunm faced several complex technical challenges based on the client's requirements:
1. Wide range of product specifications
- Minimum size: 50 × 50 × 2 mm
- Maximum size: 350 × 400 mm
- Maximum weight per item: 3 kg
2. Large number of sorting exits
- 41 normal sorting exits
- 1 exception exit
3. High difficulty in identifying dark-colored clothing
Black or dark-colored clothing is prone to misidentification in traditional visual recognition systems.4. High system integration requirements
Sorting instructions originate from the client's proprietary RFID reading system, requiring stable and real-time data exchange.5. Strict safety and compliance requirements
Including emergency stop systems, safety barriers, protective panels, and compliance with local electrical standards.
Drop Tray Sorting System Solution Design
In response to the challenges mentioned above, Gosunm has customized a high-performance tray-based sorting system solution for this project.
The core features of the system design include:
- Single-sided manual loading design, optimizing workflow and reducing operator fatigue
- Direct-drop sorting structure, where goods are directly dropped into collection bins after sorting, eliminating the need for chutes
- Adjustable tray opening angle (0–80°), adaptable to different garment characteristics
- Tray height of 1350 mm from the ground, conforming to ergonomic principles
- The Bomb bay sorting system achieves a sorting efficiency of no less than 5000 pieces/hour while ensuring stability, meeting the demands of peak operating periods.
Drop Tray Sorting Equipment Configuration
| Item | Configuration Details |
|---|---|
| Drop Tray Sorting Line | 1 set |
| Sorting Outputs | 41 standard sorting outlets |
| Exception Outlet | 1 exception outlet equipped with grayscale sensor |
| Drop Trays Quantity | 91 trays |
| Tray Expanded Size | 520 × 400 mm (±2 mm tolerance) |
| Max Load per Tray | 5 kg |
| Tray Structure | Perforated trays with bottom lighting to improve detection of dark garments |
| Collection Bin Size | 400 × 600 mm |
| Discharge Method | Sorted items drop directly into collection bins |
| Conveyor System Structure | Double-layer conveyor design |
| Horizontal Conveying | Powered roller conveyor |
| Inclined Conveying | Belt conveyor |
| Safety Protection | All conveyors equipped |
System Highlights
This Bomb-bay type sorting system integrates several mature technologies and safety designs from Gosunm:
- Siemens PLC control system
- Industrial computer + genuine Windows 11 operating system
- Multi-language human-machine interface (Chinese/English/Hebrew)
- Emergency stop button + pull-cord emergency stop system
- A set of three-color indicator lights for every 4 sorting outlets
- Independent button indicator lights for each outlet
- Low-carbon steel partitions between outlets to effectively prevent mis-sorting
- The entire machine features a carbon steel structure with industrial-grade coating for durability and reliability
Delivery & Commissioning
Before shipment, Gosunm conducted complete factory testing and inspection of the equipment, including:
- Structural and assembly inspection
- Electrical control system commissioning
- Sorting logic simulation testing
- Sample compatibility testing
The equipment power supply is 220V, and the plug and electrical configuration have been adapted to the local operating environment to ensure quick installation and commissioning upon arrival.
Subsequently, we will cooperate with the customer for on-site acceptance testing, focusing on confirming:
- Consistency with the configuration and solution
- Sorting efficiency and accuracy
- Stable, safe, and reliable system operation
Results & Feedback
Through factory testing and simulated operation, the system has achieved:
- Stable sorting efficiency ≥5000 pieces/hour
- Accurate sorting execution driven by RFID data
- Good adaptability to garments of different colors and sizes
- Significantly reduced manual sorting intensity
This project further validates Gosunm's technological maturity and engineering delivery capabilities in the field of garment sorting automation.
Why This Drop tray sorting Solution Works？
The core reasons why this solution is effective are:
- Designed entirely around the unpackaged garment sorting scenario
- Seamless integration with the customer's existing RFID system
- High sorting port density + stable control logic
- Emphasis on safety, protection, and user experience
- Integrated support from design and manufacturing to delivery provided by Gosunm
This is not just a piece of equipment, but a complete logistics sorting system solution that can operate stably for the long term.
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