Why Parcel Automation Must Adapt to Smaller, Irregular Items

E-commerce is changing the physical profile of logistics. Sorting centres now handle a growing mix of small cartons, flexible bags, cylindrical products and other irregular parcels alongside conventional boxes. Individually, these items are modest; collectively, they are testing the assumptions built into established automation systems.

The issue was discussed by Paul Hamblin and Eurosort’s Gert Jan Veelenturf during a recorded conversation at Parcel and Post Expo in London. Their central question was practical: can existing facilities process tomorrow’s parcel volumes when the equipment was designed for a more predictable flow?

Automation under pressure

Traditional sorters generally perform best when items fall within familiar dimensions and shapes. A wider product mix can affect induction, identification, routing and discharge, creating exceptions that reduce the efficiency of an otherwise automated line. Simply installing more automation does not necessarily resolve those constraints if the underlying technology is poorly matched to the parcels entering the building.

For operators, the objective is therefore broader than replacing manual work. Automation can enable the same site and workforce to process substantially more volume, an increasingly important proposition as warehouse space becomes more expensive and labour is harder to secure. Improving throughput within the existing footprint may be more realistic than continually expanding buildings or staffing levels.

From robotic induction to smarter exits

The discussion also considers where parcel handling could develop over the next five years. Robotic induction may take on a larger role at the front of the process, while sorter exits could become more automated and capable of managing a wider range of items. Such developments would need to combine mechanical flexibility with reliable control and monitoring.

For industrial companies investing in distribution capacity, the lesson is clear: parcel automation should be assessed against the actual variability of the flow, not only its nominal speed. The competitive advantage will come from extracting more capacity, resilience and usable floor space from systems designed for the realities of modern e-commerce.