Sorter Station Moves Product in Any Direction


MODSORT modular transfer and diverter accommodates a wide variety of products in any direction but does so while eliminating the need for a lift or pneumatics while being easily integrated into new or existing material handling systems.


The MODSORT conveyor station features the System Plast 2253RT roller top belt, which allows the conveyor station to uniquely transfer and divert packages based on the sphere’s vector speed and direction while also featuring a 1-in., on-center sphere array to allow for very small packages to be diverted. The matrix of freely rotating balls embedded into a continuous flat belt allows the rolling top belt station to divert and transfer products of any kind by using precise, controlled, and impact-free motion to divert and transfer products on motorized conveyor lines. The station can divert on the fly or stop and divert at a 90-deg. angle and is ideal for polybags and small packages while also easily handling boxes. MODSORT conveyor stations can be placed end to end to create a medium-rate sorter or integrated with conveyors to create transfer stations within conveyor systems. Customization is possible for picking and packing stations within a modern distribution center. Additionally, retrofitting the station into existing conveyor systems is also possible.


In addition to reducing shipping and handling costs associated with using a tray to transfer polybags, the MODSORT conveyor station can help achieve energy savings between 50 and 60% compared to traditional conveyors when integrated with a motorized roller-based conveyor system due to its low weight and friction.


  • Motorized drive rollers (MDR) and controls that employ run-on-demand technology
  • 24V DC motor and controls that allow flexibility in wiring and control
  • The ability to divert exceptionally small packages and boxes
  • No pneumatics, lifts or Z-direction position feedback devices are needed
  • Safe, energy-efficient, quiet, and low-maintenance operation
  • Controls that allow stand-alone programming or can interface to a PLC via network
  • No gaps or pinch points anywhere on the roller-free belt, i.e., workers have a much lower risk of injury

Application Considerations:

  • Package rates of 35-50 per minute
  • Typical package sizes less than 30” x 30”
  • Weight of 50 lbs or less
  • Control Card options:
    • Networked ERSC:
      • Discrete program capability
      • Interfaces to PLC via Ethernet IP
      • Control two MDR’s per card
      • Change motor parameters on the fly
    • Non-Network EZ24:
      • Not programmable, wired inputs to PLC
      • Control of one MDR per card 
      • Cannot change motor parameters on the fly
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