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Diverters are a simple yet powerful sortation tool used to redirect items from one conveyor path to another. Whether guiding products to packing stations, routing them to different zones, or separating SKUs for downstream processes, diverters help facilities maintain uninterrupted flow.
Conveyor diverters offer a compact design and fast actuation, making them ideal for facilities looking to automate routing without overhauling their entire conveyor system.
Unlike complete sortation systems, diverters are often deployed as targeted solutions within broader material handling strategies. They are instrumental in facilities with multiple product streams or where space constraints limit the use of larger sortation equipment.
How Diverters Work
Diverters are typically installed along conveyor lines and use mechanical or pneumatic actuators to shift items from one path to another.
Typical warehouse diverter types include:
- Pushers
- Pop-up wheels
- Sliding arms
Each diverter type is suited to different product types and throughput requirements. Sensors and control logic determine when and where items should be diverted, ensuring accurate routing with minimal disruption.
These fulfillment systems can be integrated with scanners, barcode readers, and Warehouse Control Software to support dynamic decision-making. For example, a diverter might route items based on SKU, order priority, or packaging requirements, all in real time.
Where Diverters Add Value
Diverters are often used to solve specific routing challenges within a facility. They can separate inbound and outbound flows, direct items to different packing zones, or reroute exceptions for manual handling.
This technology can offer the ability to operate at high speeds with minimal footprint and create a cost-effective method to improve operational efficiency.
Facilities that use diverters often see gains in throughput, reduced manual handling, and better use of conveyor infrastructure. Because they’re modular and easy to install, diverters can be added to existing systems with minimal disruption.
Key Benefits of Diverters
- Compact and cost-effective routing solution
- Supports dynamic decision-making based on product data
- Easily integrates into existing conveyor systems
- Reduce manual handling, improving flow efficiency
When to Use Diverters
Diverters are best suited for facilities that need to manage multiple product flows without investing in complete sortation systems. They are ideal for routing items to packing stations, separating SKUs, or handling exceptions to typical orders.
In operations where flexibility and responsiveness are key, diverters offer a practical way to automate decision points along the conveyor line.
They are also an excellent fit for facilities with limited space or budget. Because diverters can be deployed selectively, they allow for incremental automation that delivers measurable impact without requiring a complete system redesign.
Planning for Implementation
While diverters are relatively simple compared to other sortation technologies, proper planning is still essential. Product characteristics, such as size, weight, and surface material, can affect how well a diverter performs. Throughput requirements and conveyor speed must also be considered to ensure reliable operation.
Integration with control systems is another key factor. Diverters should be programmed to respond to real-time data and align with broader warehouse execution strategies.
Working with an experienced integrator helps ensure that diverters are deployed effectively and contribute to overall system performance.
KPI Solutions: Consulting, Integration, and Lifetime Support
KPI Solutions is more than a systems integrator. We’re a long-term partner in supply chain transformation, offering strategic consulting and hands-on support from concept through execution and beyond. Our team works closely with clients to evaluate operational challenges, identify the right technologies, and design systems that align with business goals.
Our commitment doesn’t end at go-live. KPI provides lifetime services that include system audits, performance optimization, software enhancements, and ongoing technical support.
Whether you’re automating a single routing point or rethinking your entire distribution strategy, KPI Solutions delivers the insight, experience, and continuity needed to keep your operation running at its best.