Frequently Asked Questions
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What is a robotic sorter and how does it work?
A robotic sorter is a fleet of AGV sorting robots that each carry a parcel from an induction station to its destination chute or bin, replacing fixed sortation conveyors with independent, software-routed robots. Addverb's Zippy robots scan each parcel at induction, follow ground markers to the right destination and drop the parcel into its chute. A fleet management system assigns routes, manages traffic and reroutes robots around obstacles in real time. -
Has a robotic sortation system been deployed in the US?
Yes, Addverb deployed a Zippy robotic sortation system for DHL Supply Chain at an apparel fulfillment center near Columbus, Ohio, going live within 8 months of project start. The system raised throughput by more than 300% and reached 99.99% order fulfillment accuracy, with Addverb's warehouse execution system managing operations end to end. It was built to absorb peak season volume despite ongoing labor shortages. -
What is the difference between a robotic sorter and a cross-belt sorter?
A cross-belt sorter is a fixed conveyor loop that diverts items into chutes, while a robotic sorter uses independent AGV sorting robots, so you change capacity and layout by adding or rerouting robots. Fixed loop sorters suit very stable, high-volume flows in a dedicated building. Robotic sorters suit growing or seasonal volumes and space-constrained sites, and they avoid a single point of failure: one Zippy stopping does not halt the rest of the fleet. -
How much does a robotic sorting system cost?
The cost of a robotic sorting system depends on throughput, number of destinations, parcel size mix and whether robots run at floor level or on a table-top platform, so Addverb sizes and prices each Zippy system per site. Because capacity comes from robot count, you can start with the fleet you need today and add robots for peak season or growth. Addverb has also delivered Zippy on a Robot-as-a-Service (RaaS) model. -
When is a robotic sorter not the right choice?
A robotic sorter is a poor fit for bulky, very heavy or non-conveyable items that exceed the robot's rated payload, which ranges from 13 lb to 80 lb. It also needs a flat floor or a table-top platform with room for the destination grid. Sites with mixed large and small items often run bulky goods on a separate conveyor or manual line and send small parcels through the robots.