All cross-docked goods are routed to a crossbelt sorter via one of 16 induction points. The sorter incorporates 338 two-tier carriages, with a potential throughput of 20,000 items per hour. Induction operators place goods onto the conveyor belt according to instructions issued via a PC screen. The induction system allows a diverse range of goods to be handled individually rather than in bulk, saving over £1 million per annum in packaging. The goods are inducted in store order and the sorter directs the correct quantity of each product line to the appropriate stores. There are 450 output lanes, three for each store, dedicated to womenswear, menswear or
childrenswear. The goods can therefore be despatched sorted in in-store destination, eliminating the need for this to be done manually at each store. With sortation complete, warehouse staff put the completed loads into tote boxes, add a barcode label and scan it prior to transfer to despatch. Any incoming goods that are not cross-docked are transferred to a high-bay warehouse for storage.
