Mobile Robots for the Sortation Close-out Process | FORTNA
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Transform Sortation
Close-Out Process with FORTNA OptiSweep™

As technology advances, businesses can capitalize on new automated solutions that combine efficiency and innovation. Discover the advantages of using the FORTNA OptiSweep™ robotic solution in your distribution center.

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According to the International Federation of Robotics, the transportation and logistics industry is now the largest application area for robots, accounting for 52% of deployments.1 E-Commerce represents one of the most significant use cases, driven by the need for rapid fulfillment and, more broadly, by the growing demand for automation to improve operational efficiency and address labor shortages in the logistics sector.2

In this context, mobile robots are becoming a necessity, particularly in environments where speed, accuracy and scalability are critical. They bring measurable benefits across multiple processes, from inbound receiving and internal transportation to sorting, outbound shipping and returns processing.

Close-out sortation: an opportunity for improvement

In the high-speed environments of e-Commerce and sortation centers, the close-out sortation process still relies heavily on manual labor and extensive walking within the warehouse. Advanced automation can deliver significant efficiency and workplace improvements: operations become more agile and faster, and operators can reduce unnecessary movement and manual effort.

Die FORTNA OptiSweep™ robotic solution automates the consolidation and transportation of small orders away from sortation systems. This innovation reduces labor requirements and eliminates the need for workers to bend and reach into bags to move items. It also significantly cuts the time spent walking through the warehouse.

Deployments of the OptiSweep™ robotic solution have demonstrated a 60% reduction in manual labor associated with sorter clearance operations, with a payback period of around two years in these business cases. Thanks to its modular design and the absence of a single point of failure, the system can remain operational 24/7.

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The FORTNA OptiSweep™ robotic solution transforms a traditionally manual process into a streamlined, scalable operation helping customers sustain high throughput while reducing labor dependency. Its modular design allows for phased deployment and seamless integration, delivering reliable performance with minimal disruption to existing operations. Our approach with OptiSweep™ is grounded in real operational needs: productivity, uptime and scalability. Empowered by advanced control software, the solution gives customers the flexibility they need to respond quickly to changing demand while maintaining consistent, continuous performance.

Harvey Dhillon

VP Business Development and Growth Leadership, LPS

Knowledge and expertise that make the difference

The OptiSweep™ solution integrates a Geekplus mobile robot, leveraging the full potential of the FORTNA and Geekplus partnership. “Bringing together FORTNA’s extensive knowledge of distribution operations and Geekplus’ advanced robotics expertise, this collaboration provides customers with a differentiated, knowledge-driven automation advantage,” says Dhillon.

FORTNA OptiSweep™ can be deployed in both greenfield and brownfield environments, where it can replace legacy technologies, such as the bombay sorter. The advantages include full utilization of sorter capacity, increased throughput and improved operational accuracy. The solution supports a wide range of throughput requirements, offering processing flexibility from 4,000 to more than 35,000 pieces per hour.

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Geekplus’ Tote-to-Person P40 robot integrated into the FORTNA OptiSweep™ solution is built to keep totes and cartons flowing to the point of work so packing and dispatch can stay paced, even under peak seasons. With a strong partnership, FORTNA and Geekplus offer a perfect solution for unpredictable demands and peak season operations, which is very difficult to handle with manual operations.

Brad Kilian

Channels Sales Manager for Geekplus EMEA

Mobile robot technology

In parcel fulfilment, one of the key pain points is variability: order waves spike without warning, SKU profiles shift and operators spend too much time walking or waiting for the next task. “Geekplus’ Tote-to-Person P40 robot integrated into the FORTNA OptiSweep™ solution is built to keep totes and cartons flowing to the point of work so packing and dispatch can stay paced, even under peak seasons,” says Brad Kilian, Channels Sales Manager for Geekplus EMEA. “With a strong partnership, FORTNA and Geekplus offer a perfect solution for unpredictable demands and peak season operations, which is very difficult to handle with manual operations,” says Kilian.

At the hardware level, the P40 is small, fast and purpose-built for tote handling. With a maximum payload of 40 kg, a maximum speed of 3.5 m/s and a minimum lifting time of 4 seconds, this robot offers an efficient automation process while reducing the picking time. Its lift is designed for short, ergonomic presentation up to 440 mm and features compact dimensions (650 × 450 × 386 mm) and a weight of 60 kg. In other words, it is engineered for rapid cycles in dense pick/pack areas.

That design maps cleanly to parcel operations. The P40 helps convert “search and travel” time into “pick and pack” time by bringing the right tote to the right workstation at the right moment, allowing sites to scale by adding or removing robots as demand changes. The result is a parcel flow that is easier to balance across stations, less dependent on fixed conveyor layouts and better aligned with the pace of outbound cutoffs.

Powered by intelligent software

The OptiSweep™ robotic solution moves items efficiently from the sorter to the operator. Each stage of the process is powered by FORTNA WCS™ software, which seamlessly orchestrates workflows by managing mobile robots and coordinating communication with the sorter and consolidation stations to maximize efficiency and balance product flow.

When the sorter diverts items toward a designated chute, a mobile robot exchanges the tote, removing the full container and positioning an empty one in its place. Once secured, the mobile robot transports the tote to the operator station, delivering it precisely where it is needed and reducing operational time and manual handling.

At the station, a tipper empties the tote into a bag, enabling fast and controlled unloading of sorted items. After unloading, the mobile robot returns the empty tote to the sorter, ready for the next cycle. This closed-loop process supports continuous operation and high throughput.

The solution is compatible with both tray-based and non-tray sorters, making it flexible and easy to integrate.

Reliable automation for consistent performance

Built on real-world deployment knowledge, the FORTNA OptiSweep™ robotic solution combines deep expertise and proven experience with a distinctive automation approach designed to optimize sorting and material flow operations. It delivers reliable performance and adapts easily to different operational environments. Comprehensive service and support further ensure smooth implementation, continuous optimization and long-term system reliability, allowing customers to focus on their operations with confidence.

FORTNA an Ihrer Seite

With deep expertise in automation, software and robotics, FORTNA partners with logistics organizations committed to elevate their operations. By uniting warehouse process expertise with a strong focus on technological advancement, FORTNA delivers solutions designed around your operational goals.

Rethink Close-Out
<sup>1</sup> <a href="https://ifr.org/ifr-press-releases/news/service-robots-see-global-growth-boom/" target="_blank" rel="noopener">https://ifr.org/ifr-press-releases/news/service-robots-see-global-growth-boom/</a><br /> <sup>2</sup> <a href="https://www.factmr.com/report/mobile-industrial-robot-market" target="_blank" rel="noopener">https://www.factmr.com/report/mobile-industrial-robot-market</a>

 

Published/Updated 2/23/26