Innovate Distribution’s manual sortation lines were the bottleneck of their entire fulfillment operation. During peak periods, sorters made classification errors that cascaded into misroutes, returns, and customer complaints. The facility processed 35K packages/day but needed to hit 100K+ to win new contracts.
IntelliSyncs deployed a machine learning-based vision system that classifies and routes packages in real-time — reading labels, measuring dimensions, and diverting to the correct chute in under 200ms. The ML model was trained on 2 million package images and continuously improves from every new scan. The system replaced 12 manual sortation stations with 4 AI-powered lines.
Measurable impact, delivered
Every metric verified against baseline — not projections, production numbers.
Stack powering this deployment
The systems, platforms, and integrations that made this project possible.
“Our sortation bottleneck disappeared overnight. The system learns from every package — accuracy keeps improving. We’re handling 3× the volume with half the footprint.”