Small parcels expose the next challenge for logistics automation

Industrial logistics is entering a period in which parcel variability matters as much as parcel volume. E-commerce networks increasingly move small, lightweight and irregular items alongside conventional cartons. At scale, this mixture can challenge the mechanical and operational assumptions embedded in established sorting facilities.

The issue was explored by Paul Hamblin and Eurosort’s Gert Jan Veelenturf at Parcel and Post Expo in London. Their discussion highlighted a strategic problem for operators: systems built around predictable formats must now cope with a flow that is considerably less uniform.

Capacity is a systems question

Unusual shapes and low-weight items can affect induction, recognition, routing and sorter discharge. These are interconnected steps, so a weakness at one point can reduce the performance of the entire line. Adding automation without addressing compatibility with the parcel mix may therefore create complexity rather than resilience.

The business case for modernisation is also broader than labour substitution. Operators need to process more volume through existing sites, using the available workforce more effectively. This matters as industrial and warehouse space becomes more costly and recruitment becomes harder. Better throughput within the current footprint can improve resilience while delaying the need for major expansion.

Designing for adaptability

The next five years may bring greater use of robotic induction and increasingly automated sorter exits. These developments could reduce manual intervention, but their value will depend on how well they respond to real operating conditions and changing product profiles.

For Industry 5.0 strategies, this is a reminder that automation should support adaptable operations rather than pursue speed in isolation. Facilities must combine machine capability with effective monitoring, practical human oversight and the ability to accommodate variation. A sorting system that performs well only with standard cartons may be fast, but it is not necessarily future-ready.