Pop-up Sorters

Fast, Flexible, Footprint-Saving – Inline Sorting at Its Simplest

System Introduction

Pop-up Sorters are compact, modular, and highly adaptable sortation devices that use vertical lifting mechanisms to raise rollers, belts, or wheels at sorting junctions. When activated, these units “pop up” from beneath the conveyor line to redirect items along the desired outbound path — either at a 30° or 90° angle, depending on the layout. This type of system is often installed at key diversion points along a main conveyor, offering reliable on-the-fly item redirection without halting upstream flow.

Known for their space-efficient design and versatility, pop-up sorters are ideal for applications that require selective lane switching, destination-based dispatching, or infeed/outfeed zoning within compact facilities. They’re commonly used in e-commerce parcel handling, pharmaceutical packaging, grocery distribution, and reverse logistics operations.
Pop-up modules can work as standalone units or be integrated into conveyor matrix layouts, and are often controlled via PLC systems, ensuring accurate, synchronized switching.

Application Scenarios

E-commerce Fulfillment

Fast, inline redirection of parcels based on order ID or shipping method. Boosts picking line speed sortation.

Pharma & Cosmetics

Precise and gentle sorting for small, sensitive products in cleanroom or GMP environments.

Retail Distribution

Modular diverting for outbound dispatch in DCs. Supports case or tote sortation by store or category.

Returns Processing

Dynamic sorting of return goods based on scanning, condition, or restocking status.

Food & Beverage Lines

Inline carton diversion for packing, labeling, or palletizing zones without halting flow.

Features & Advantages
Structure & Components

Key Features & Advantages Designed for compact, high-efficiency warehouse sortation, LEADOR’s Pop-up Sorters deliver fast, accurate, and safe product diversion at a fraction of the space and cost required by larger sortation systems. They are ideal for retrofitting into existing conveyor layouts or being part of a new system design. Compact Inline Sortation Without Line Stops Pop-up mechanisms are embedded directly into conveyor frames, enabling real-time sorting at transfer points without halting the main flow — ideal for continuous processing and high throughput needs. Flexible Sorting Angles Available in 30° and 90° configurations, pop-up sorters easily adapt to complex facility layouts, allowing for dual-sided discharges, custom zoning, or multi-directional routing. Wide Package Compatibility Whether it’s small e-commerce parcels, medium-size cartons, or returnable plastic totes, the system is engineered for reliable sorting across a wide range of shapes, sizes, and surface materials. Low Maintenance, High Uptime With fewer moving parts and accessible pop-up modules, these sorters offer low failure rates, minimal wear-and-tear, and fast maintenance access, reducing system downtime significantly. Quiet and Ergonomic Operation Noise-dampened actuation and smooth mechanical lift make this system worker-friendly, especially important in facilities with long sorting lines or human-machine collaborative zones.

A typical Pop-up Sorter unit consists of: Main Conveyor Segment: Standard belt or roller conveyor where items pass normally. Pop-up Mechanism: A powered unit (roller set, belt, or wheel) installed beneath the conveyor; vertically actuated. Actuation Unit: Driven by electric motor, pneumatic cylinder, or servo-controlled lift. Divert Lane: Conveyor or gravity chute to guide diverted items to sorting zone. Control System: Logic-based activation through PLC/SCADA or sensor-triggered response. Sensors & Triggers: Detect product position and initiate diversion at the correct moment.

Technical Specifications

Parameter	Value
Max Throughput	2,500 – 5,000 pcs/hour per unit
Actuation Speed	< 0.5 seconds
Item Size Range	200 × 200 mm to 800 × 600 mm
Max Item Weight	Up to 35 kg
Divert Angles	30°, 45°, 90°
Drive Type	Electric / Pneumatic / Servo
Control Interface	PLC / Sensor Trigger

Applications & Case Studies

Discover how Leador has empowered businesses to achieve their logistics goals. Explore our detailed case studies showcasing real-world implementations and measurable results

Pharmaceutical Sorting Line

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Pop-up Sorters in Action

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Compatibility, Safety & Support

Safety is a core design principle for our Pop-up Sorters. We integrate essential safety features compliant with international machinery directives and safety standards (e.g., EN ISO 13849). This includes protective guarding, emergency stop buttons, and intelligent sensor monitoring to prevent personnel interaction with moving parts and ensure safe operation. The robust mechanical design ensures high reliability and consistent performance with minimal downtime.

Leador Tech offers complete, end-to-end support for your Pop-up Sorter investment. Our service spans from initial system design and layout consultation to professional installation, precise calibration, and comprehensive operator training. Our dedicated global service network provides rapid response times for technical assistance, remote diagnostics capabilities, and efficient on-site support. We also provide tailored preventive maintenance programs and guarantee timely spare parts availability to maximize your system’s uptime and extend its operational lifespan.

Leador Tech provides comprehensive, end-to-end support for your Sliding Shoe Sorter investment. Our service extends from initial consultation and customized system design to professional installation, rigorous commissioning, and thorough operator training. Our dedicated global service network ensures rapid response times for technical assistance, remote diagnostics capabilities, and efficient on-site support. We offer tailored preventive maintenance programs and guarantee timely spare parts availability to maximize your system’s uptime and ensure its long-term operational excellence.