{"id":7166,"date":"2026-07-01T11:53:56","date_gmt":"2026-07-01T09:53:56","guid":{"rendered":"https:\/\/bkls.de\/project\/sorting-conveyor-system\/"},"modified":"2026-08-04T08:37:07","modified_gmt":"2026-08-04T06:37:07","slug":"sorting-conveyor-system","status":"publish","type":"project","link":"https:\/\/bkls.de\/en\/project\/sorting-conveyor-system\/","title":{"rendered":"Sorter Conveyor System"},"content":{"rendered":"

[et_pb_section fb_built=”1″ fullwidth=”on” _builder_version=”4.27.6″ background_color=”#2ea3f2″ use_background_color_gradient=”on” background_color_gradient_direction=”330deg” background_color_gradient_stops=”#2ea3f2 0%|#2e6df4 100%” background_color_gradient_start=”#2ea3f2″ background_color_gradient_end=”#2e6df4″ border_radii=”on|30px|30px|30px|30px” global_colors_info=”{}”][et_pb_fullwidth_header title=”Custom Special Machine Construction and Intelligent Conveyor Technology \u2013 Perfectly Combined” subhead=”for automated identity verification and IO\/NIO sorting” content_max_width=”none” _builder_version=”4.27.6″ title_font=”Source Sans Bold – BKLS||||||||” title_text_align=”left” subhead_font=”Source Sans Semi Bold – BKLS||||||||” subhead_text_color=”gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7″ background_color=”gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891″ custom_margin=”||1px|||” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22background_color%22%93,%22gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7%22:%91%22subhead_text_color%22%93}” button_one_text_size__hover_enabled=”off” button_two_text_size__hover_enabled=”off” button_one_text_color__hover_enabled=”off” button_two_text_color__hover_enabled=”off” button_one_border_width__hover_enabled=”off” button_two_border_width__hover_enabled=”off” button_one_border_color__hover_enabled=”off” button_two_border_color__hover_enabled=”off” button_one_border_radius__hover_enabled=”off” button_two_border_radius__hover_enabled=”off” button_one_letter_spacing__hover_enabled=”off” button_two_letter_spacing__hover_enabled=”off” button_one_bg_color__hover_enabled=”off” button_two_bg_color__hover_enabled=”off”][\/et_pb_fullwidth_header][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”4.16″ custom_padding=”||0px|||” global_colors_info=”{}”][et_pb_row column_structure=”1_2,1_2″ _builder_version=”4.16″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” custom_padding=”9px|||||” global_colors_info=”{}”][et_pb_column type=”1_2″ _builder_version=”4.16″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_text _builder_version=”4.27.6″ text_font=”Source Sans Regular – BKLS||||||||” text_font_size=”16px” header_2_font=”Source Sans Bold – BKLS||||||||” background_size=”initial” background_position=”top_left” background_repeat=”repeat” global_colors_info=”{}”]<\/p>\n

Customer requirement<\/h2>\n

For the incoming goods area of film-wrapped flat goods, an automated solution was required that reliably identifies items, detects faulty products, and sorts them without manual intervention. RFID, barcode, and AI-supported code reading technologies needed to be integrated into a continuous conveying process. At the same time, the system had to be seamlessly integrated into existing conveyor technology and the current IT landscape, and serve as a scalable prototype for future expansion stages. <\/p>\n

[\/et_pb_text][\/et_pb_column][et_pb_column type=”1_2″ _builder_version=”4.16″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_text _builder_version=”4.27.6″ text_font=”Source Sans Regular – BKLS||||||||” text_font_size=”16px” header_2_font=”Source Sans Bold – BKLS||||||||” background_size=”initial” background_position=”top_left” background_repeat=”repeat” global_colors_info=”{}”]<\/p>\n

Our solution<\/h2>\n

BKLS developed a fully automated sorter conveyor system that combines the expertise of conveyor technology and special machine construction<\/strong> into a tailor-made overall solution. The system handles the identity verification of film-wrapped flat goods and the automatic separation of IO and NIO items. <\/span><\/p>\n

The system combines several conveyor modules with intelligent sensors, RFID and barcode detection, and automated rejection of faulty products. Conveyor technology, control technology, and individual machine design seamlessly interlock, enabling a continuous, secure material flow. <\/p>\n

All conveyor belts, sensors, and sorting processes are coordinated via the integrated Siemens S7 control system. Communication with KEYENCE and identass identification systems takes place via defined interfaces, ensuring reliable real-time evaluation. The system is supplemented by safety devices according to the Machinery Directive, container and fill level monitoring, and remote maintenance options. <\/p>\n

[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”1_3,1_3,1_3″ _builder_version=”4.16″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” locked=”off” global_colors_info=”{}”][et_pb_column type=”1_3″ _builder_version=”4.16″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_number_counter title=”less manual sorting and inspection effort” number=”90″ counter_color=”#2ea3f2″ _builder_version=”4.27.6″ title_font=”Source Sans Semi Bold – BKLS||||||||” title_text_color=”gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7″ title_font_size=”20px” number_font=”Source Sans Semi Bold – BKLS||||||||” number_text_color=”gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22number_text_color%22%93,%22gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7%22:%91%22title_text_color%22%93}”][\/et_pb_number_counter][\/et_pb_column][et_pb_column type=”1_3″ _builder_version=”4.16″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_number_counter title=”Process reliability through automated identity verification” number=”100″ counter_color=”#2ea3f2″ _builder_version=”4.27.6″ title_font=”Source Sans Semi Bold – BKLS||||||||” title_text_color=”gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7″ title_font_size=”20px” number_font=”Source Sans Semi Bold – BKLS||||||||” number_text_color=”gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22number_text_color%22%93,%22gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7%22:%91%22title_text_color%22%93}”][\/et_pb_number_counter][\/et_pb_column][et_pb_column type=”1_3″ _builder_version=”4.16″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_number_counter title=”faster incoming goods processes” number=”40″ counter_color=”#2ea3f2″ _builder_version=”4.27.6″ title_font=”Source Sans Semi Bold – BKLS||||||||” title_text_color=”gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7″ title_font_size=”20px” number_font=”Source Sans Semi Bold – BKLS||||||||” number_text_color=”gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22number_text_color%22%93,%22gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7%22:%91%22title_text_color%22%93}”][\/et_pb_number_counter][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”4.27.6″ background_color=”#f7f7f7″ background_color_gradient_direction=”330deg” border_radii=”on|30px|30px|30px|30px” box_shadow_style=”preset1″ global_colors_info=”{}”][et_pb_row column_structure=”1_2,1_2″ _builder_version=”4.27.6″ background_color=”gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” custom_padding=”|10px||10px|false|false” border_radii=”on|30px|30px|30px|30px” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22background_color%22%93}”][et_pb_column type=”1_2″ _builder_version=”4.27.6″ custom_padding=”50px||||false|false” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_text _builder_version=”4.27.6″ text_font=”Source Sans Bold – BKLS||||||||” text_text_color=”#FFFFFF” background_size=”initial” background_position=”top_left” background_repeat=”repeat” global_colors_info=”{}”]<\/p>\n

Technical highlights<\/span><\/h1>\n

[\/et_pb_text][et_pb_blurb title=”Automatic IO\/NIO sorting using conveyor and paddle system” use_icon=”on” font_icon=”+||divi||400″ icon_color=”gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7″ icon_placement=”left” _builder_version=”4.27.6″ header_font=”Source Sans Semi Bold – BKLS||||||||” header_text_color=”#FFFFFF” background_size=”initial” background_position=”top_left” background_repeat=”repeat” background_layout=”dark” animation=”right” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22body_text_color%22,%22icon_color%22,%22body_text_color%22%93,%22gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7%22:%91%22icon_color%22%93}”][\/et_pb_blurb][et_pb_blurb title=”RFID, HF, UHF, and AI-supported barcode recognition” use_icon=”on” font_icon=”||fa||900″ icon_color=”gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7″ icon_placement=”left” _builder_version=”4.27.6″ header_font=”Source Sans Semi Bold – BKLS||||||||” header_text_color=”#FFFFFF” background_size=”initial” background_position=”top_left” background_repeat=”repeat” background_layout=”dark” animation=”right” image_max_width=”none” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22body_text_color%22,%22icon_color%22,%22body_text_color%22,%22icon_color%22,%22body_text_color%22%93,%22gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7%22:%91%22icon_color%22%93}”][\/et_pb_blurb][et_pb_blurb title=”Siemens S7 control with HMI, remote maintenance, and interface integration” use_icon=”on” font_icon=”||divi||400″ icon_color=”gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7″ icon_placement=”left” _builder_version=”4.27.6″ header_font=”Source Sans Semi Bold – BKLS||||||||” header_text_color=”#FFFFFF” background_size=”initial” background_position=”top_left” background_repeat=”repeat” animation=”right” image_max_width=”none” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22body_text_color%22,%22icon_color%22,%22body_text_color%22,%22icon_color%22,%22body_text_color%22%93,%22gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7%22:%91%22icon_color%22%93}”][\/et_pb_blurb][et_pb_blurb title=”Conveyor speed up to 25 m\/min” use_icon=”on” font_icon=”||fa||900″ icon_color=”gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7″ icon_placement=”left” _builder_version=”4.27.6″ header_font=”Source Sans Semi Bold – BKLS||||||||” header_text_color=”#FFFFFF” background_size=”initial” background_position=”top_left” background_repeat=”repeat” animation=”right” image_max_width=”none” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22body_text_color%22,%22icon_color%22,%22body_text_color%22,%22icon_color%22,%22body_text_color%22%93,%22gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7%22:%91%22icon_color%22%93}”][\/et_pb_blurb][\/et_pb_column][et_pb_column type=”1_2″ _builder_version=”4.16″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_image src=”https:\/\/bkls.de\/wp-content\/uploads\/2026\/07\/D.jpg” title_text=”D” align_tablet=”center” align_phone=”center” align_last_edited=”on|desktop” _builder_version=”4.27.6″ custom_margin=”50px||||false|false” animation_style=”slide” animation_direction=”left” animation_duration=”500ms” animation_intensity_slide=”10%” border_color_all=”#FFFFFF” animation=”left” global_colors_info=”{}”][\/et_pb_image][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”4.16″ custom_padding=”0px||0px|||” global_colors_info=”{}”][et_pb_row column_structure=”1_3,2_3″ _builder_version=”4.27.6″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” custom_margin=”||10px||false|false” custom_padding=”||10px||false|false” global_colors_info=”{}”][et_pb_column type=”1_3″ _builder_version=”4.16″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_text _builder_version=”4.27.6″ _module_preset=”default” text_font=”Source Sans Semi Bold – BKLS||||||||” text_text_color=”gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891″ text_font_size=”20px” ul_font=”Source Sans Semi Bold – BKLS||||||||” background_color=”gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7″ custom_padding=”10px|10px|10px|10px|false|false” animation_style=”bounce” animation_duration=”1200ms” animation_delay=”50ms” border_radii=”on|15px|15px|15px|15px” global_colors_info=”{%22gcid-3621c07e-b5a1-4b56-9820-3675ce8dd891%22:%91%22text_text_color%22%93,%22gcid-7fa51e00-1a91-4b64-a46a-95719d404fa7%22:%91%22background_color%22%93}”]<\/p>\n

Cycle time:
3 seconds per part
<\/em><\/p>\n

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The automated sorter conveyor system resulted in a tailor-made overall solution that combines conveyor technology, special machine construction, and intelligent automation<\/strong> in one system. Automated identity verification and sorting reduce manual interventions, increase process reliability, and ensure continuous material flow. Thanks to its modular design and open interface architecture, the system can be flexibly integrated into existing production and logistics processes while also forming the basis for future expansion stages. <\/p>\n

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We develop individual conveying and automation solutions for secure, efficient, and future-proof production and logistics processes.<\/p>\n

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Customer requirement For the incoming goods area of film-wrapped flat goods, an automated solution was required that reliably identifies items, detects faulty products, and sorts them without manual intervention. RFID, barcode, and AI-supported code reading technologies needed to be integrated into a continuous conveying process. At the same time, the system had to be seamlessly […]<\/p>\n","protected":false},"author":2,"featured_media":7165,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_et_pb_use_builder":"on","_et_pb_old_content":"","_et_gb_content_width":"","footnotes":""},"project_category":[27],"project_tag":[],"class_list":["post-7166","project","type-project","status-publish","has-post-thumbnail","hentry","project_category-special-machine-construction"],"_links":{"self":[{"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/project\/7166","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/project"}],"about":[{"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/types\/project"}],"author":[{"embeddable":true,"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/comments?post=7166"}],"version-history":[{"count":3,"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/project\/7166\/revisions"}],"predecessor-version":[{"id":7171,"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/project\/7166\/revisions\/7171"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/media\/7165"}],"wp:attachment":[{"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/media?parent=7166"}],"wp:term":[{"taxonomy":"project_category","embeddable":true,"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/project_category?post=7166"},{"taxonomy":"project_tag","embeddable":true,"href":"https:\/\/bkls.de\/en\/wp-json\/wp\/v2\/project_tag?post=7166"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}