Warehouse Bridge
Put Wall Systems (PTW)
Lights show you exactly which order slot to put each item. Perfect for multi-order fulfillment. Plug-and-play installation—mount it yourself, no specialized contractors. No more mis-sorts. No more wrong orders going out.
The Multi-Order Sorting Problem
When you're fulfilling multiple orders simultaneously, keeping items sorted correctly is a nightmare.
Mis-Sorted Orders
Item goes in the wrong order. Customer A gets Customer B's product. Expensive mistakes.
Cognitive Overload
Workers juggling 10-30 orders mentally. "Which slot is order #47632?"
Slow Throughput
Constant checking and rechecking. Scanning labels. Looking up order numbers.
Batch Size Limits
Can't scale beyond 5-10 orders at once without chaos. Leaves throughput on the table.
How Put Wall Systems Work
A wall of slots (cubbies). Each slot represents one order. Lights tell you exactly which slot each item belongs in.
Batch Picked
Items for multiple orders picked together (often using PTL for picking)
Scan Item
Worker scans item barcode at put wall station
Light Shows Slot
Correct order slot lights up. No thinking required.
Place & Confirm
Put item in lit slot, press button. Light turns off. Repeat.
Typical Configuration
- 20-50 slots - Process 20-50 orders simultaneously
- Modular design - Start small, add more walls as volume grows
- Visual & audible cues - Lights plus optional beeps for confirmation
- Integration with WMS - Real-time order status updates
- Banner Electronics hardware - IP67-rated, built for 24/7 operation
Perfect For
E-Commerce Fulfillment
High-volume, multi-order operations where speed and accuracy both matter.
Ideal when:
- Hundreds of small orders daily
- Orders share common SKUs
- Same-day shipping expectations
Retail Distribution
Sorting items for multiple store locations from a central DC.
Ideal when:
- Batch picking for store replenishment
- Need to sort to 20+ locations
- Mixed-SKU shipments per location
3PL Multi-Client
Consolidating orders for multiple clients efficiently.
Ideal when:
- Serving multiple end clients
- Each client has different SKUs
- Need clear order separation
How Teams Use Put Walls
Scan-Based Sorting
Worker scans each item before placing it.
Process:
- Scan item barcode
- System lights up correct slot
- Place item, press confirm button
- Light turns off, ready for next item
Best for: High accuracy requirements, mixed SKUs, audit trail needed
Pre-Sorted Batches
Items pre-sorted by order, lights confirm correct placement.
Process:
- Pick batch for one order
- Scan order to activate slot light
- Place all items in lit slot
- Confirm complete, move to next order
Best for: Orders with multiple items, when pick accuracy is already high
Wave-Based Processing
Process orders in waves, clear wall between waves.
Process:
- Load wave 1 (e.g., 30 orders)
- Sort all items to slots
- Pack and ship wave 1
- Load wave 2, repeat
Best for: Scheduled shipping cutoffs, managing packing station capacity
Continuous Flow
Orders continuously flowing through, slots auto-reassign.
Process:
- Order complete? System signals packer
- Packer removes order from slot
- Slot automatically assigned to next order
- Continuous operation
Best for: High-volume operations, maximizing throughput
What This Means for Your Bottom Line
Sort Accuracy
Near-perfect order accuracy. Lights eliminate sorting errors.
Batch Size
Process 3-5x more orders simultaneously vs. manual sorting.
Faster Sorting
Typical improvement in items-per-hour throughput.
ROI Timeline
Payback from labor savings and error reduction.
Industrial-Grade Hardware
Put walls run all day, every day. We use Banner Electronics IP67-rated components because they're built for continuous warehouse operation.
- Dustproof & waterproof - IP67-rated protection
- 24/7 reliability - Built for continuous operation
- Easy maintenance - Modular components, simple replacement
- Scalable design - Add more slots as volume grows
Ready to Scale Your Order Consolidation?
Let's talk about your operation. We'll show you exactly how a put wall would work with your order volumes and which configuration makes the most sense.