Entertainment Sorter – Multi-Media Sorter

CD, DVD, Cassette, and Video Tape – High Speed Tilt Tray Sorter

Here we present a sample application CD Sorter, DVD Sorter, Multi-Media Sorter, Entertainment Sorter - all combined into this High Speed Tilt Tray Sortation System that was specifically designed to sort Multi-Media and Entertainment Products such as a CD, DVD, Video Tape, and Cassette.

This High Speed Tilt Tray Sortation System is used for applications including; Order Fulfillment, Returns and Loose Receipts Processing – utilizing automatic induction, Label Printers, and stacking chutes.

Benefits - of CD Sorter, DVD Sorter, Video Tape Sorter, Cassette Sorter – Multi-Media Sorter

• Automatically and reliability sort individually packaged and bar coded products - 
  - such as a CD, DVD, Cassette or Video Tape (Entertainment & Multi-Media Products) 
• Greatly reduce labor costs associated with manual sortation and verification
• Greatly reduce the time needed to assemble individual product by order or other criteria
• Expand the sort window
• Recover more warehouse space
• Simultaneously sort mixed shaped products.

Common Features - of Sorter for CD Sorter, DVD Sorter – Multi-Media Sorter

• Rates of up to 12,000 trays per hour
• Adjustable Automatic Induction Units
  Brackets are adjustable to the product being inducted
  Loaders can simultaneously feed various product sizes within specific ranges 
   - such as a CD, DVD, Cassette or Video Tape (Entertainment & Multi-Media Products) 
• Divert Capable Chute Design
  Bottom chute collects and stacks CD's
  Top chute collects all other items
  Chutes may be manually or automatically diverted
• Sorter is capable of labeling product as it is sorted
• Windows^™ 2000 system with Microsoft SQL database

AUTOMATIC INDUCTION -  for CD, DVD, Video Tapes, Cassettes – Multi-Media Products (Uniform Products)

GBI manufactures several forms of automatic induction depending on product configuration and type of sortation method. In all cases the product is dispensed onto sorter trays or into sorter carriers to help approach the maximum throughput provided by the sorter. Where several automatic induction units are employed a central control system is used to coordinate each induction unit to release product on available trays taking into account which trays have already been loaded. Generous use and placement of sensors help ensure that product is flowing properly.

High Speed Tilt Tray Sorter Automatic Induction Unit

GBI's tilt tray sorters have the capability of sorting product at rates exceeding 12,000 trays per hour making it difficult to manually load product directly onto the sorter. A typical application of this auto-induction unit is for entertainment media such as CD's, DVD's, cassettes and video tapes but may be used whenever package sizes are uniform..

Automatic Induction Unit -  for CD, DVD, Video Tapes, Cassettes – Multi-Media Products (Uniform Products)

The automatic feeders are used to receive the product and automatically induce them onto the sorter. CD's, cassettes, videotapes or DVD's are loaded in stacks onto each auto-feeder. Each feeder may be adjusted using two quick release clamps for the size of product to be fed. Redundant feeders are provided so that they may be configured for different product types. Bar codes are loaded in the face up position for disposition to the vision system scanner specifically designed to scan entertainment products.

Each feeder has an associated push button that is used to indicate to the control system that the feeder is loaded and ready to begin automatic induction. Once depressed the feeder will automatically dispense the product onto the next available tray. The sorter controls help ensure that only one item is loaded per tray.

Each pneumatic feeder will hold over 60 single CD units and discharge product at a maximum approximate rate of one piece per second provided that an empty tray is available. Since the throughput capacity of the sorter is approximately one piece every 0.33 seconds, the sorter capacity will require only three feeders operating simultaneously to keep up with the sorter rate of 12,000/trays per hour. We have provided an extra feeder for each operator to allow the operators time to load one feeder while the other is dispensing product for a continuous flow of product to help approach the rate of the sorter and to provide redundancy. Product may be loaded onto the auto induction units even while it is in the process of dispensing product.

Automatic Label Printer Applicators  - for CD, DVD, Video Tapes, Cassettes – Multi-Media Products

Three or more automatic label printer applicators may be placed in line along the tray path. The combined speed of the applicators will be capable of labeling the passing product at the sorter tray rate of approximately 12,000 trays per hour or 200 pieces per minute. Each label applicator will have the maximum capability to independently print and apply a label at a rate of approximately 100 labels per minute for a combined maximum throughput of 300 labels per minute thereby exceeding the sorter rate.

GBI utilizes a third party label printer applicator and integrates it with the sorter controls to work in concert with the sorter system. Labels may be unique and are printed on demand as required on an item-by-item basis.

Stacking Chutes - for CD, DVD, Video Tapes, Cassettes – Uniform Products

GBI also manufactures stacking collection chutes, for uniform products, that have the capacity to hold over 60 single CD or DVD products. A stainless steel chute receives the product and orients it appropriately for stacking. A diverter located at the center of the chute is left open to receive a CD to the stacker or is closed to allow other product to pass over and accumulate in the collection chute above as shown here.

The diverter may be manually positioned by way of a lever. A CD, DVD would be run first to the stackers since it makes up the vast majority of the volume, and then the diverter would be closed to sort all the remaining product to the chute.

Alternatively, the manually operated diverter may be replaced with a pneumatically operated and electronically controlled diverter to automatically separate the CD or DVD from the other products as it is randomly delivered to the drop location. The sorter controls automatically raise and lower the diverter on demand according to the type of product received. A pneumatic air cylinder is employed to move the diverter door quickly as needed.

Each chute has a Lexan door to visually monitor the stacking progress and to provide access to remove the collected product.

Chute Full Sensors & Status Displays

Each chute may be equipped with a chute full sensor to sense when product has accumulated to a full condition. Upon detecting this accumulation the sorter controls will suspend the effected chute to prevent any other product from entering the chute and backing up into the moving trays. Chute full beacons may also be provided to illuminate when this condition occurs to alert personnel to empty the chute. Upon clearing the sensor, by removing product, the chute would automatically revert back to a normal condition and turn off the chute full beacon.

See Tilt Tray Sorters for additional information on this High Speed Tilt Tray Sortation System -  used in this sample application to sort - CD, DVD, Video Tapes, Cassettes - Multi-Media - Entertainment Products

See "Sorter Applications" for some examples of applications or processes that are greatly improved through automation using GBI's Sortation Systems.

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GBI Data & Sorting Systems • 1143 West Newport Center Drive • Deerfield Beach, FL 33442 USA
+1 (954) 596-5001 • Fax +1 (954) 596-5015 • E-mail contact: info@gbisorters.com