Quick Answer: The OPEX Sure Sort® is an automated robotic sorting system that uses self-charging iBOT® robots to sort up to 2,400 items per hour in as little as 1,000 sq ft of floor space. It reduces manual labour by 45–60%, achieves 99.8%+ order accuracy, and can be installed in as little as one week. Smarter Automated Solutions is OPEX’s exclusive Australian partner.

 

If your warehouse team is still manually sorting items into orders — or relying on outdated put-wall systems that bottleneck throughput — you’re leaving efficiency on the table. As e-commerce volumes surge and customer expectations tighten, the pressure on distribution centres to sort faster, more accurately, and with fewer people has never been greater. This guide covers everything you need to know about the OPEX Sure Sort®: how the technology works, what it costs to justify, real-world Australian results, and how to determine if it’s the right fit for your operation.

What Is the OPEX Sure Sort®?

The OPEX Sure Sort® is a fully automated robotic sorting system designed for order consolidation, batch pick sorting, and returns processing in distribution centres. It uses OPEX’s proprietary iBOT® autonomous delivery vehicles to replace manual sorting workflows, delivering enterprise-level throughput in approximately 1,000–1,500 square feet — a fraction of the footprint required by traditional conveyor-based sorters.

Unlike traditional conveyor systems that require large footprints and complex infrastructure, the Sure Sort is modular, scalable, and can be installed in as little as one week. It is suited to mid-size and large operations across e-commerce, apparel, 3PL, and returns processing.

How Does the OPEX Sure Sort® Work?

The Sure Sort works by inducting items onto a conveyor, scanning and measuring each one, then dispatching autonomous iBOT robots to carry items to the correct destination bin — at up to one item per second. The process requires 1–3 staff members compared to the 5–10+ typically needed for manual sorting.

Here is the step-by-step sorting process:

  1. Induction — Items enter the system via a conveyor induction module. The system scans each item, measures its dimensions (maximum 6-inch item height, 3-inch gap between items), and assigns it a destination bin.
  2. Routing — An iBOT receives real-time routing instructions and navigates the enclosed grid to deliver the item. iBOTs can update their destination mid-route, dynamically optimising throughput as conditions change.
  3. Delivery — A drop conveyor accelerates items for precise delivery at up to one item per second.
  4. Pack notification — When an order is complete, the pack-to-light system illuminates an LED indicator at the relevant bin, signalling staff that the order is ready for packing and despatch.

How Do iBOT Robots Recharge?

iBOT robots are self-charging using ultra-capacitor technology that captures energy during braking, meaning they recharge continuously during normal operation. There are no manual battery swaps, no scheduled downtime, and no charging stations to manage. This is a key differentiator from competing robotic sorting systems that require battery replacement or docking cycles.

What Are the OPEX Sure Sort® Specifications?

  • Maximum throughput: Up to 2,400 units per hour (UPH)
  • Induction speed: Up to 1 item per second
  • Item weight (standard): Up to 5 lbs
  • Item weight (extended): Up to 20 kg
  • Maximum item height at induction: 6 inches
  • Footprint (high throughput): ~1,000–1,500 sq ft
  • Installation time: As little as 1 week
  • Environmental range: Ambient and chilled environments
  • Scalability: Add iBOTs to increase throughput
  • Order accuracy: 99.8%+

The modular architecture means the system ships in configurable, stackable units that can be installed and commissioned significantly faster than traditional sortation infrastructure, and expanded incrementally as volume grows.

What Industries Use the OPEX Sure Sort®?

The Sure Sort is used across e-commerce fulfilment, apparel and fashion, third-party logistics (3PL), returns processing, and health and beauty distribution. Any operation with high SKU variety, high daily order volumes, or labour-intensive manual sorting is a strong candidate.

 

E-Commerce Fulfilment

High SKU variety, unpredictable volumes, and same-day/next-day despatch requirements make e-commerce one of the most demanding environments for manual sorting. The Sure Sort automates order consolidation from batch picks across hundreds of SKUs simultaneously.

 

Apparel and Fashion

Apparel DCs contend with enormous SKU counts, poly-bagged items, and size/colour/style matrix sorting. The Sure Sort processes up to 2,400 items per hour — a rate manual operations cannot match — while reducing pick errors and labour costs significantly.

 

Third-Party Logistics (3PL)

3PLs managing multiple client inventory streams benefit from the Sure Sort’s compact footprint and scalable throughput. One OPEX 3PL customer reduced labour requirements by 50% while maintaining 1,500 items per hour consistently — directly improving their fulfilment contract margins.

 

Returns Processing

The Sure Sort accelerates returns sorting, reducing backlog and returning stock to sellable inventory faster — a critical capability as e-commerce return rates in Australia average 20–30% (Australia Post, 2024).

 

Eyewear, Cosmetics, and Health Products

Smaller, irregularly shaped items that resist easy barcode scanning work well with the Sure Sort’s induction system. It can be paired with RFID scan tunnels for poly-bagged or shrink-wrapped items.

What Results Has the OPEX Sure Sort® Delivered in Australia?

The first OPEX Sure Sort installation in Australia was deployed at NPFulfilment in 2018 by Smarter Automated Solutions. The result: a batch pick and order consolidation process that previously required eight employees now runs with three — a labour saving of over 60%.

NPFulfilment has since grown to six warehouses across Australia and New Zealand. Their story is one of the most documented examples of warehouse automation success in the ANZ region, demonstrating what is achievable when automation is matched correctly to operational requirements.

Across Sure Sort deployments globally, operators typically report:

  • 45–60% reduction in manual labour requirements
  • 99.8%+ order accuracy
  • ROI realised within 18–24 months

How Does the OPEX Sure Sort® Compare to Manual Sorting?

Metric Manual Sorting OPEX Sure Sort®
Throughput 200–600 UPH per team Up to 2,400 UPH
Labour required 5–10+ staff at peak 1–3 staff
Error rate High (human fatigue) Minimal (automated)

What Is the ROI on the OPEX Sure Sort®?

The Sure Sort delivers ROI through five value drivers: labour cost reduction, error elimination, throughput speed, space efficiency, and rapid deployment. Most operations realise full ROI within 18–24 months.

  • Labour cost reduction — Up to 2,400 UPH replaces multi-person manual sorting teams, directly reducing your largest operational cost.
  • Error elimination — Automated sorting removes mispicks and mis-sorts, reducing customer service costs and returns handling.
  • Throughput speed — Handle peak season, flash sales, and promotional spikes without temporary staff or despatch slowdowns.
  • Space efficiency — At 1,000–1,500 sq ft, the Sure Sort fits facilities that cannot accommodate traditional conveyor sortation.
  • Rapid deployment — Modular design means installation and commissioning in as little as one week, minimising operational disruption.

Is the OPEX Sure Sort® Right for Your Operation?

The Sure Sort is best suited to operations processing 500 or more orders per day, with high SKU variety, labour bottlenecks, or limited floor space. It is particularly strong for 3PLs, e-commerce fulfilment centres, and apparel DCs.

Consider the Sure Sort if your operation meets one or more of these criteria:

  • Processing 500+ orders per day with manual sorting creating bottlenecks
  • High SKU variety across apparel, e-commerce, or multi-category fulfilment
  • Need to reduce labour dependency without sacrificing throughput or accuracy
  • 3PL operator seeking to improve cost structure and service levels
  • Handling returns volume that requires faster processing back to sellable stock
  • Seasonal or growth-driven volume spikes requiring scalable capacity
  • Limited floor space that cannot accommodate traditional conveyor infrastructure

Frequently Asked Questions About the OPEX Sure Sort®

What is the OPEX Sure Sort®?

The OPEX Sure Sort® is an automated robotic sorting system that uses self-charging iBOT® robots to sort items into destination bins for order fulfilment. It processes up to 2,400 units per hour in approximately 1,000–1,500 square feet of floor space, with 1–3 staff members required.

 

How fast is the OPEX Sure Sort®?

The Sure Sort sorts up to 2,400 units per hour (UPH), with an induction speed of up to one item per second via the drop conveyor system. This compares to 200–600 UPH for a typical manual sorting team.

 

How much space does the OPEX Sure Sort® require?

The Sure Sort requires approximately 1,000–1,500 square feet for high-throughput operation — significantly less than traditional conveyor-based sortation systems, making it accessible to mid-size operations and facilities with constrained floor space.

 

How long does OPEX Sure Sort® installation take?

Due to its modular design, the Sure Sort can be installed and operational in as little as one week. This is significantly faster than traditional automation projects, which often require months of infrastructure work.

 

How do Sure Sort iBOT robots recharge?

iBOT robots use ultra-capacitor technology to capture energy during braking, recharging continuously during normal operation. No manual battery swaps or charging downtime are required.

 

What is the OPEX Sure Sort® ROI timeframe?

Most operations deploying the Sure Sort realise full return on investment within 18–24 months, primarily through labour cost reduction, error elimination, and increased throughput capacity.

 

Who is the OPEX Sure Sort® Australian partner?

Smarter Automated Solutions is OPEX Corporation’s exclusive authorised partner in Australia. They have been deploying Sure Sort systems since 2018, including the first-ever Sure Sort installation in Australia at NPFulfilment.

 

Can the OPEX Sure Sort® operate in chilled environments?

Yes. The Sure Sort is rated for both ambient and chilled environments, making it suitable for cold-chain fulfilment operations.

 

What items can the OPEX Sure Sort® sort?

The Sure Sort handles items up to 5 lbs (standard) or 20 kg (extended capacity), with a maximum item height of 6 inches at induction. It accommodates irregular shapes and sizes, and can be paired with RFID scan tunnels for poly-bagged or shrink-wrapped items.

 

How does the Sure Sort compare to traditional put-walls?

Traditional put-walls require manual labour to sort items into bays. The Sure Sort replaces this with autonomous iBOT robots, achieving 4–12x the throughput with 60–80% fewer staff, near-zero error rates, and continuous operation without fatigue.

How Smarter Automated Solutions Can Help

Smarter Automated Solutions is OPEX Corporation’s authorised partner in Australia, with over 80 years of combined industry experience in warehouse automation design, consultancy, project management, and turnkey implementation.

We designed, supplied, and commissioned Australia’s first Sure Sort installation in 2018 and have deployed multiple systems across Australia since then. We work with operations across 3PL, e-commerce, retail distribution, apparel, and health products.

Whether you’re exploring the Sure Sort as a standalone sorting solution or integrating it into a broader automation strategy including goods-to-person systems, conveyor networks, and warehouse control software, our team delivers systems that perform from day one.

Ready to see what the OPEX Sure Sort® could do for your operation?

Contact the Smarter Automated Solutions team to arrange a consultation or live product demonstration.

Contact us at: sales@smarteras.com.au

 

Smarter Automated Solutions is an authorised partner for OPEX Corporation in Australia, providing design, supply, and implementation of warehouse automation systems including the Sure Sort®, Perfect Pick®, and associated material handling solutions.

Tags: OPEX Sure Sort, warehouse automation Australia, automated sorting system, iBOT robots, e-commerce fulfilment automation, 3PL automation Australia, put-wall alternative, robotic sorting system, order fulfilment technology, distribution centre automation