Semi-automated bulk sorting system and associated methods

A sorting center for sorting outbound parcels and cartons comprising:

• a center walkway;
• a plurality of sorting stations elevated from the center walkway;
• a plurality of infeed chutes for automatically diverting the outbound parcels and cartons down one of the plurality of infeed chutes to a designated sorting station;
• and
• a plurality of takeaway chutes coupled to a plurality of conveyors and each conveyor terminates at a plurality of carton palletization zones;
• wherein the plurality of takeaway chutes have upper ends adjacent to the plurality of sorting platforms and lower ends feeding the plurality of conveyors, and the plurality of sorting platforms are positioned for a sorter to manually move the cartons from a respective sorting platform and down one of the plurality of takeaway chutes.

A method of manufacturing a semi-automated bulk sorting system comprising:

• providing a primary conveyor having a proximate end and a distal end, the proximate end of the primary conveyor configured for collecting outbound parcels and cartons that are to be sorted;
• coupling a plurality of infeed chutes between the distal end of the primary conveyor and a plurality of sorting stations in series along the primary conveyor with each infeed chute having an upper end connected along the primary conveyor and a lower end terminating at a designated sorting station of a plurality of sorting stations;
• positioning a first takeaway chute of a plurality of takeaway chutes forward on a first side of the designated sorting station;
• positioning a second takeaway chute forward on a second side of the designated sorting station;
• positioning a third takeaway chute rearward on the first side of the designated sorting platform;
• positioning a fourth takeaway chute rearward on the second side of the designated sorting station;
• positioning a small sorts lane above and forward of the plurality of sorting stations;
• and
• positioning a plurality of carton palletization zones downstream from the plurality of takeaway chutes and being configured to receive the sorted cartons via a respective conveyor in order to palletize the sorted cartons for delivery by a designated carrier.