Systems and methods for sorting objects to large numbers of orders

An object processing system comprising:

• a primary sortation system that receives a plurality of objects at a plurality of infeed stations and includes a loop conveyance system that moves the plurality of objects around a closed loop that includes a plurality of primary sortation exits at which any of the plurality of objects is selectively discharged from the primary sortation system;
• a secondary sortation system inside the closed loop of the primary sortation system, the secondary sortation system including a plurality of vertically stacked shuttle modules, each shuttle module including a reciprocating conveyance for moving a received object of the plurality of objects via a selected primary sortation exit of the plurality of primary sortation exits from a first end of the respective shuttle module to any of a plurality of destination bins or totes of the respective shuttle module;
• and
• a plurality of output conveyors, each of which is positioned adjacent a shuttle module, and each of the reciprocating conveyances including a bin or tote removal system for selectively moving a selected bin or tote from the plurality of destination bins or totes from the respective shuttle module onto an adjacent output conveyor of the plurality of output conveyors,
• wherein the bin or tote removal system comprises a kicker arm capable of being rotated to contact with the selected bin or tote and push the selected bin or tote onto the adjacent output conveyor.

A method of processing objects comprising:

• moving a plurality of objects toward a primary sortation system that includes a closed loop conveyance system for moving the plurality of objects generally along a first input direction;
• diverting the plurality of objects at a plurality of primary sortation exits of the primary sortation system to a plurality of cache diverters that comprise a plurality of belted conveyors;
• moving the plurality of objects on the belted conveyors of the plurality of cache diverters to a plurality of reciprocating conveyances of a plurality of shuttle modules in a secondary sortation system inside the closed loop conveyance system, each belted conveyor leading to one of the plurality of shuttle modules of the secondary sortation system, wherein the plurality of belted conveyors include independently controllable sections such that each of cache diverters provides that any object thereon will arrives at a first end of the respective shuttle module when a respective reciprocating conveyance of the respective shuttle module is also at the first end of the respective shuttle module;
• moving the plurality of objects on the plurality of reciprocating conveyances to a plurality of destination bins or totes provided in the plurality of shuttle modules;
• ejecting the plurality of objects from the plurality of reciprocating conveyances into selected bins or totes among the plurality of destination bins or totes of the plurality of shuttle modules;
• ejecting one or more of the plurality of destination bins or totes of the plurality of shuttle modules to a plurality of output conveyors;
• and
• moving the ejected destination bins or totes on the plurality of output conveyors to at least one output location outside of the closed loop conveyance system.