Bomb Bay Sorter • Carrier-Style Sorter

The GBI Bomb Bay (carrier-style) sorter provides the highest density of sort destinations in the market today for the range of package sizes it handles. The system is quiet, efficient, low maintenance and highly accurate.

Bomb Bay Sorter (Carrier-Style) shown with optional automatic induction "Synchro-Loader" Click on image for enlarged view

See a video of the GBI Bomb Bay  (Carrier-Style) Sorter

Methodology
Packages are scanned and loaded into clear Lexan™ carriers, which transports the product to assigned interior and exterior sort positions. There are 96 sort points in every 7 x 10 foot sort section when using the 3.5-inch chute center configuration. The carrier conveys the product in a vertical orientation and releases the product (bomb bay style) to either an inside or outside sort point for accumulation. Typical product applications for this sorter include photo finishing envelopes, drugs, videotapes, optical lenses, small envelopes or catalogs.

Package Configuration
This sorter is available with 3.5", 5.25", or 7.0" chute centers and 1.5 or 3.0 inch wide carrier openings according to accumulation or product requirements. This is the preferred sorter for applications utilizing packages less than 3 inches thick, 6.75 inches wide and 13 inches high because of the high density of drops for a given floor space, resulting in a lower equipment cost.

Sorter Configuration

Sorter Layout

Sorter Expansion Chart

To enable the sorter to transport a variety of package sizes, the carriers on this sorter come in two sizes and handle product measuring either: 13" high x 6.75" wide x 1.5" deep or 13" high x 6.75" wide x 3.0" deep Controls and Accuracy A generous amount of strategically placed sensors and controls are employed to monitor the conditions of the sort. There are sensors above the chutes to indicate if the product did not properly deploy into the chute and verification sensors to verify that the product released entered the appropriate chute. Drop verification is included with every carrier-based sorter to help assure a high accuracy rate. GBI strives for 100% accuracy. Our customers report accuracy rates up to and exceeding 99.99%, with verification. Other sensors monitor cart position and automatically suspend a sort to any location where the cart has been removed. Product that is destined to a suspended location is reversed out of the database and the product is sent to the “all-drop" (jackpot) for reinduction. Carts are employed to gain access the inside cartons or mailbags. The chute status screens around the sorter are employed to report the status of those locations and carts may be removed to gain access to those locations when appropriate.

Click on image for enlarged view Click on image for enlarged view

Status Displays

There are monitors all around the sorter reporting the condition of the sort both for that zone and to bring attention to other zones around the sorter. Messages include errors, warnings and sort status. The sort status includes pertinent information based on the users requirements and may include one or several of the following:

• Order Number
• Amount Sorted
• Amount Remaining To Be Sorted
• Chute Status As Suspended (cart removed) or Order Complete

Sorter Software:
The software used to drive the GBI Tilt Tray Sorters is built on a Windows NT/2000 system platform using Microsoft SQL for data storage. Aside from being user friendly, our sorter software in concert with the GBI sorter controls permit a high degree of programming flexibility. Included with these systems is the additional functionality to allow you to keep track of product by chute and subsequently by package.

Safeguards: Software safeguards are in place to protect the integrity of the sort as well as the maintenance of the equipment. We presently check that a solenoid was triggered to confirm the sort request and stop the sorter under extreme conditions that may affect the reliability of the sort or the equipment condition, such as a possible chain jam.

Tracking Software: Sorted data is recorded in a database that tracks each package including:

• every sku seen by the scanner
• the time it was seen
• whether it got a valid read or not
• the tray it traveled on
• to which drop it was directed
• mode of operation (automatic or manual)
• on which cycle of the sorter
• where it was dispensed
• was the solenoid triggered to drop or canceled.

Reliability
This sorter has been termed our Simple Solution Sorter™ for its simple construction and ease of maintenance. It has evolved through three generations and there are almost 50 carrier based sorters in use around the world in companies such as Wal-Mart, Qualex (a Kodak company), Fuji, Litto Color, and Deluxe check printers with more slated for delivery in the coming months. The first one delivered over eighteen years ago is still in operation today, as are most of the others.

Many of these sorters are operated six to seven days a week and up to 22 hours per day with minimal maintenance. Several are installed with auto-induction, and still others will be installed with cross plant conveyors with auto induction from our pricing equipment.

As with all GBI's sorters, we can customize our software to integrate with various host systems to communicate pertinent information for process matching, reporting, tracking and productivity measurement. For instance, the photo finishing and optical application ofthis sorter will match sorted product against a host provided pricing or process status to confirm that the product has been priced or properly completed before allowing it to ship.

Numerous configurations are available should it be necessary to turn corners, accommodate package sizes or rate requirements.

Greatest Benefits of Carrier Based Sorter

• High Accuracy
• Low Maintenance
• High Density
• Small Footprint
• Low Cost - per drop
• Quiet Operation

Some examples of other sorter types :

• Tilt Tray Sorter
• Cross Belt Sorter
• Pick-to-Light
• Hanging Garment Sorter

Applications and processes that are greatly improved through automation using GBI's Sortation Systems

• Loose Receipts Application
• Order Fulfillment Application
• Returns Application
• Zip Code Application
• Mail Sorter

DEFINITION contributed by GBI to: www.wikimheda.org
A Carrier Sorter is a mechanical device that transports any shape product that can fit into a specific carrier dimension. The carrier conveys the product in a vertical orientation and releases the product (bomb bay style) to either an inside or outside sort point for accumulation. This type of sorter provides the highest density of sort destinations with the smallest foot-print, as the direction of travel is smallest dimension of the product or items being sorted. Products or items may be sorted based on a specified criteria.

Summary of all GBI Sortation Systems : Sorter Types

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GBI Data & Sorting Systems • 1143 West Newport Center Drive • Deerfield Beach, FL 33442 USA
954-596-5000 Ext. 231 • Fax 954-596-5015 • E-mail contact: info@gbisorters.com