Warehouse Bridge Hardware
Put Walls (PTW)
A grid of cubby slots, one per active order. Pickers do mixed-SKU batch picks. The wall lights the correct cubby on scan; when it goes solid green, that order is complete and ready to pack.
A put wall is a grid of cubby slots, one slot per active order. Pickers do batch picks of mixed SKUs and bring the tote to the wall. They scan an item, the correct cubby lights up, they drop the item in, and they move to the next one. When a cubby goes solid green, that order is complete and ready to pack. It's the difference between sorting 30 orders in your head and sorting them with your eyes.
Put walls are the right answer for any operation running mixed-SKU batch picking — same-day e-commerce fulfilment, retail replenishment to 20+ stores from a central DC, multi-client 3PL operations. The constraint without a put wall isn't accuracy in the picking step — it's cognitive load in the sorting step. Once that breaks, you cap your batch size at five or six orders. With a put wall you can run 30–50 orders in a batch without errors creeping in.
The system
Three layers. One operator-visible result.
The put wall runs on the same three-layer stack as the pick-to-light system. Your WMS — Camelot today, plus other WMS on request — posts the batch wave to the Warehouse Bridge controller. The controller is a compact pre-configured appliance on a rack in your network closet. It talks to your WMS and drives the Banner gateway at the wall.
At the wall, the Banner gateway sits on the frame on 24V DC power. The wall's scan station feeds barcode data to the controller; the controller turns each scan into a "light cubby X" command and writes it down to the gateway.
Each cubby carries a Banner cubby light. Daisy-chained on industrial cabling. The light displays the cubby state — off, lit (current target), solid green (order complete, ready to pack), flashing red (mis-sort). The operator presses confirm; the press flows back up to the WMS. Banner builds the lights. We build the bridge.
What you get
Ships in one consolidated order.
- One Warehouse Bridge controller — pre-configured to your wall layout and WMS
- N Banner gateways — one per put wall
- One Banner cubby light per cubby — daisy-chained on industrial cabling
- The scan station — barcode reader wired to the controller
- The WMS integration — Camelot direct today; other WMS via CSV/API on request, with native integrations on the roadmap
- On-site install support — we walk the first wall with your team
Why this combo
Banner builds the lights. We build the bridge.
Banner builds the lights. We build the bridge. The cubby light is the same family as the pick-to-light system — one spare in your maintenance cabinet, one cable type. When a cubby light fails, the replacement is one purchase order away from an industrial distributor. Banner has been shipping these into industrial duty cycles since long before put walls became a 3PL category.
What we own is the wall logic: which cubby gets which order, what to do when a SKU scans into a cubby it doesn't belong in, how to surface a mis-sort to a supervisor in real time, and how to push the throughput numbers back into the visibility stack. That's the layer where the operator experience lives.
Install & commissioning
A day per zone. No engineering firm in the middle.
A single put wall installs in under a day with two people from your maintenance team:
- Frame the wall. Standard industrial shelving, your existing wall frame, or a Banner-recommended modular kit.
- Mount the Banner gateway on the wall frame. 24V DC power, one Ethernet drop back to the Warehouse Bridge controller. IP67, so it lives in the warehouse, not the closet.
- Daisy-chain a Banner cubby light into each cubby. Industrial cable from the gateway to the first cubby, then from cubby to cubby.
- Mount the scan station. Wired to the controller over USB or Ethernet.
- Commissioning runs itself. The controller learns the cubby map — press the button on cubby A1, controller binds it; walk the wall, done. Software commissioning runs in under an hour per wall, on top of the hardware mount above.
Key specs
What you’ll get on day one.
| Component | Spec |
|---|---|
| The controller | Pre-configured appliance, plug-and-play, mounts in your rack |
| The gateway | Banner-built, industrial-grade, IP67, 24V DC industrial |
| The cubby lights | Banner-built, one per cubby, industrial-grade, multi-colour indication, IP67, industrial daisy-chain cabling |
| Sortation speed | 40–60% faster vs manual sort |
| Cross-contamination rate | Zero — lights eliminate misplacement at the cubby level |
| Batch size | 3–5x manual sorting (30–50 orders per wave) |
| Wall size | 24 cubbies minimum, 96+ on the same controller |
| Install | Under a day per wall for a competent maintenance lead |
| Pricing | Quoted per wall — send wall size and WMS |
FAQ
The questions operators ask first.
What does a put wall cost? Quoted per wall — wall size and WMS shape it. Benchmark: a comparable 32-cubby wall from a traditional integrator typically quotes $30–60k upfront with a 10–15%/year maintenance contract on top. We come in materially below that, with hardware that ships in days and you install yourself. A wall typically pays back inside one peak season for a 3PL running mixed-SKU batch waves at scale.
How long from order to live? Three to six weeks for the first wall. Subsequent walls in a day each, sharing the same controller and WMS integration.
Can we add cubbies later? Yes — daisy-chain extra cubby lights into the existing wall. Beyond one gateway's capacity, add a second gateway to the same Warehouse Bridge controller; the controller speaks to multiple gateways without re-engineering.
Which WMSes do you support? Camelot direct today. Other WMS platforms via CSV/API on request, with native integrations on the roadmap.
What happens when a SKU scans into the wrong cubby? The cubby light flashes red on the correct cubby, the scan station shows the order ID, and an exception event flows up to the operator dashboard. Supervisor sees the mis-sort in real time, not at end-of-shift.
Pairs with
Software-integrated, not standalone.
The Warehouse Bridge visibility stack — wall throughput, slot dwell time, and per-client mis-sort events all stream into the operator dashboard. Pair with Client Scorecard to show your clients the sortation accuracy they're paying for.
Talk to us about your warehouse.
Send us a few photos of your floor, your pick volumes, and what your WMS is. We’ll tell you which of these — if any — actually makes sense for you. No deck, no quote until we agree there’s a fit.