This project serves as a benchmark for green logistics practices in the region, demonstrating how automation can drive low-carbon, sustainable development while maximizing economic output.
KENGIC Drives Efficiency in Turkey: 60% Cost Reduction and 10,000 PPH for a Famous 3PL
Case Study from | KENGIC Intelligent Technology Co., Ltd
The global e-commerce landscape is experiencing explosive growth, placing unprecedented pressure on logistics and fulfillment centers. Across the industry, traditional manual sorting methods are hitting a breaking point. Companies are facing a "perfect storm" of challenges: low efficiency that cannot handle peak order volumes, a heavy reliance on manual labor leading to rising operational costs, and frequent sorting errors that damage customer satisfaction.
Furthermore, operational environments are becoming more demanding. In regions with high temperatures and humidity, basic equipment often fails, leading to costly downtime. The industry is urgently shifting toward intelligent automation not just to scale, but to survive. The demand is clear: logistics providers need high-speed, accurate, and durable systems that reduce labor dependency and ensure business continuity under any conditions.
In the bustling industrial zone of Torbal, Izmir (Turkey), a leading local brand in logistics—undertook a critical transformation project at their Yazba warehouse.
KENGIC CBS Project in Turkey
The project was initiated to overhaul an existing manual operation that was severely limiting growth. The facility faced significant bottlenecks: a throughput capped at just 3,000 pieces per hour, an alarming sorting error rate of 10%, and a parcel damage rate of 15% due to manual handling. Additionally, the project faced a unique environmental challenge: the equipment needed to operate reliably in Izmir’s specific climate conditions, requiring high durability against heat and humidity while fitting into a specific 460-meter loop layout.
To address these pain points, the facility implemented KENGIC’s High-Speed Cross-Belt Sorter (CBS). This state-of-the-art automated sorting system was engineered specifically to replace labor-intensive processes with precision and speed.
KENGIC CBS Project in Turkey
Key features of the solution include:
- High Capacity: A 460.5-meter conveying loop featuring 576 individual carriers.
- Speed & Efficiency: Operating at 2.5 m/s, the system is designed to handle a peak processing capacity of over 10,000 items per hour.
- Intelligent Handling: The system supports a wide range of parcel sizes (SKU compatibility) with an abnormal item response time of less than 1 second.
- Durability: The CBS is built to withstand high-temperature and high-humidity environments, ensuring stable performance where other systems might falter.
- Predictive Maintenance: Integrated software monitors equipment health in real-time to prevent unexpected downtime.
Transitioning from a manual setup to a fully automated high-speed loop involves more than just hardware installation; it requires a cultural and operational shift. One of the critical "behind the scenes" focuses of this project was ensuring the system's longevity in the local climate. The engineering team didn't just install a sorter; they implemented a solution capable of "self-monitoring" through predictive maintenance.
KENGIC CBS Project in Turkey
The project timeline, spanning from planning in late 2024 to final implementation in December 2025, allowed for meticulous calibration. The result is a system that doesn't just sort packages but actively helps the operations team manage workflow by identifying abnormal items instantly, a leap in technology that creates a much smoother day-to-day operation for the warehouse staff.
The implementation of the KENGIC CBS system at the Trendyol Izmir facility has delivered transformative results, turning a bottleneck into a competitive advantage:
KENGIC CBS Project in Turkey
- Throughput Skyrocketed: Sorting efficiency jumped from 3,000 pieces per hour to 10,174 pieces per hour—more than tripling capacity.
- Accuracy Achieved: The mis-sorting rate plummeted from 10% to a near-perfect 0.01%.
- Quality Protection: Parcel damage rates were reduced from 15% to 0.01%, significantly boosting end-customer satisfaction.
- Cost Optimization: The project achieved a 60% reduction in labor costs and decreased the unit parcel processing cost by approximately $0.3.
This project serves as a benchmark for green logistics practices in the region, demonstrating how automation can drive low-carbon, sustainable development while maximizing economic output.
KENGIC Intelligent Technology Co., Ltd. is a leading global provider of intelligent logistics and smart manufacturing solutions. We specialize in cutting-edge automation technologies, including high-speed cross-belt sorters, conveying systems, and intelligent software integration. Our mission is to empower businesses worldwide to achieve higher efficiency, lower costs, and sustainable growth through the power of automation.
The content & opinions in this article are the author’s and do not necessarily represent the views of ManufacturingTomorrow
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