Combination of Bulk Flow Optimizer and SmartPath Singulator and Gapper provides field-proven, small-footprint alternative to singulators that require staffing

• Zero-operator singulation solution transforms 3D bulk flow of packages into a properly gapped, single-file stream – eliminating need for manual intervention before automated sorters
• Bulk Flow Optimizer meters package flow to eliminate stacked packages and instantaneous, uneven bursts of throughput that cause overfeeding of the downstream singulator and sorter
• Pairing Bulk Flow Optimizer together with SmartPath Singulator and Gapper delivers field-proven throughput of over 7,500 packages per hour

Intralox® showcases an automated solution for zero-operator package singulation at MODEX 2026 in Atlanta, targeting the needs of postal and parcel facilities and e-commerce distribution centers. At booth B9913, the company is highlighting its Bulk Flow Optimizer™ and SmartPath™ Singulator and Gapper, which work in tandem to provide a fully automated solution to prepare incoming bulk package flow for automated sortation systems, delivering high throughput in a compact footprint.

“If you look at singulation offerings for parcel hubs and e-commerce fulfillment centers, our zero-operator offering is unique for its combination of compact footprint, low price point and ability to actually meet performance requirements without an operator,” says Stephen Moseley, Sales Manager, Logistics Business Unit, Intralox. “Space and labor are two major forces that shape logistics operations, and this solution provides exceptional throughput and the flexibility to meet layout requirements, while reducing their exposure to a limited warehouse workforce.”

The key to the compact footprint is SmartPath, an Activated Roller Belt™ (ARB™) solution that consolidates both singulation and gapping functions in a single, compact piece of equipment, preparing 2D bulk package flow to be merged into a single-file stream for an automated sorter. With a length of just 8 feet, SmartPath requires up to 42% less space compared to other solutions. It can also momentarily hold or slow packages to match induction rates to the downstream sorter, helping avoid jams and maximizing overall throughput with no manual intervention required.

The Bulk Flow Optimizer fits earlier in the process, just ahead of SmartPath. It takes disorganized, 3D bulk flow directly from gaylord tippers or other upstream processes, and conditions them in a way that optimizes the performance of SmartPath. It removes vertical stacks to provide a 2D package flow, and meters package streams to smooth out uneven bursts that can overfeed the downstream singulator and sorter. This capability enables a zero-operator singulation process that provides relief from labor challenges and avoids the inconsistencies of manual processes, ultimately boosting singulator and sorter performance.

Controls integration is a key component of the combined solution, with all logic for delayering, metering, buffering, singulation and gapping consolidated and fully tuned to work together. The zero operator singulation solution is a prime example of how the company’s technology integrates together seamlessly to provide maximum value. The Intralox bulk-to-sorted product line offers a range of solutions engineered to address the evolving needs of parcel and warehouse operations for induction, singulation, gapping and sortation.