Order fulfillment system and method with sortation at induct

An order fulfillment system, comprising:

• a warehouse that is adapted to store of plurality of inventory items and a data base adapted to store a plurality of customer orders and the inventory items making up the customer orders,
• wherein some of the orders being a single item order having only one inventory item assigned to that order and other of the orders being multiple item orders having multiple inventory items assigned to that order;
• an identifier adapted to identify inventory items withdrawn from the warehouse and to apply the identity of that inventory item to the data base for matching of that inventory item with an order;
• a sortation system that is responsive to the data base to combine inventory items together that make up an order;
• an induct subsystem having an input;
• a transportation system adapted to transport inventory items from the warehouse to said input;
• said induct subsystem being responsive to said data base to separate inventory items into individual inventory items and forward individual inventory items assigned to multiple-item orders individually to said sortation system,
• said sortation system comprising a buffer that is adapted to accumulate individual inventory items and an accumulator that is adapted to receive inventory items from said buffer when all or a portion of the inventory items that make up a multiple item order are in said buffer, wherein said sortation system comprises a pouch sorter having individual pouches connected with an overhead conveyor, said overhead conveyor adapted to route pouches, wherein said induct subsystem supplies individual inventory items making up a portion of a multiple item order to a pouch;
• and
• said induct subsystem being responsive to said data base to forward inventory items assigned to single item orders to a packing station bypassing said sortation system, wherein said induct subsystem includes a bulk flow conveyor and, wherein said induct subsystem sends inventory items assigned to a single-item order to said bulk flow conveyor;
• wherein said induct subsystem includes an automated pouch opener and wherein said pouch opener is responsive to said data base to open a pouch to receive an individual inventory item of a multiple item order and is responsive to said data base to not open a pouch for an inventory item of a single-item order wherein said bulk flow conveyor is subjacent said pouch opener, wherein an inventory item supplied to a non-opened pouch falls to the bulk flow conveyor.