Warehouse Sorting: How Diggipacks & Fastcoo Systems Tie Fulfillment Together

logistic solutions

Sorting might not be the flashiest part of ecommerce logistics, but in reality it’s one of the most critical levers behind speed, accuracy, and stability in fulfillment.

At Diggipacks, sorting is not just people moving boxes around. It is an operational logic embedded inside our unified logistics systems powered by Fastcoo – from the moment inventory is received to the moment an order is handed off to the right carrier.

What Is Warehouse Sorting?

Warehouse sorting is the process of organizing and routing products inside a fulfillment center so that every item reaches:

  • The right location

  • At the right time

  • Via the right path

In Diggipacks, this is orchestrated by Fastcoo cloud logistics stack (WMS / OMS / Last Mile), which unifies storage, fulfillment, last-mile aggregation, and COD flows on a single platform.

Core Concepts – As Implemented in Fastcoo

Sortation

Rules inside Fastcoo that group items and orders by:

  • Destination

  • Carrier

  • Service level (standard / express / cold)

  • Product type

Routing

Fastcoo determines the optimal path:

  • From receiving

  • To storage

  • To picking zones

  • To packing stations

  • To the correct outbound dock or carrier lane

Put-away

The WMS suggests and enforces smart put-away locations based on:

  • Turnover velocity

  • Size and weight

  • Product family

This directly impacts future picking and sorting efficiency.

Picking & Packing

Picking waves and packing queues in Fastcoo are built using the same sortation logic:

  • Grouped by carrier, region, or priority

  • With on-screen instructions to reduce human decision-making and error

How Sorting (Through Fastcoo) Impacts Performance

When sortation rules are baked into the system instead of staying in people’s heads:

  • Delivery speed improves (fewer decision points, less back-and-forth).

  • Operational cost per order drops (less walking, less rework).

  • Order accuracy goes up (system-driven checks at each step).

  • Customer experience benefits from faster, more reliable final delivery.

Diggipacks leverages this by running all fulfillment flows on top of Fastcoo  unified SaaS platform.

The Main Sorting Stages in a System-Driven Operation

Inbound Sorting

As inventory is received:

  • Items are scanned into Fastcoo

  • Classified by product type and storage profile

  • Assigned to optimal storage zones via put-away rules

Bad inbound sorting shows up later as:

  • Slow picking

  • “Phantom stockouts” (stock exists but is misplaced)

Order Sorting

Once orders enter the system:

  • Fastcoo groups them into waves based on:

    • Carrier

    • Service level

    • Destination region

  • Picking tasks are generated in logical routes for operators

This reduces congestion and makes packing much more predictable.

Outbound Sorting

After packing:

  • Parcels are routed (logically, inside Fastcoo) to:

    • The right staging area

    • The right carrier manifest

    • The correct dock or handover point

Outbound sortation errors = expensive delays and re-shipments.
System-driven outbound sortation = clean handoff, clean tracking, clean reporting.

Sorting Methods – With Systems in Mind

1) Manual Sorting

Still useful for:

  • Special items

  • Low-volume SKUs

  • Edge cases

But always backed by the system as the source of truth.

2) Semi-Automated Sorting

In Diggipacks-style operations, this usually means:

  • Conveyors, racks, and structured workstations

  • Plus Fastcoo screens, scanners, and device prompts

  • Humans execute; the system decides.

3) Fully Automated Sorting (Industry Level)

Described here as an industry model, not as our current setup:

  • High-speed cross-belt / tilt-tray / robotics

  • Requires deep WMS integration and high, stable volumes

Fastcoo’s architecture is designed to integrate with such automation if and when it becomes relevant.

4) Hybrid Solutions

The realistic, scalable model:

  • Use system logic (Fastcoo) for decisions

  • Use people + light mechanics (conveyors, scanners) for execution

  • Grow automation gradually as volume justifies it

5) Specialized Sorting

Fastcoo flags SKUs and orders that need special handling:

  • Fragile

  • Temperature-controlled

  • High-value

  • Regulated

These flags drive:

  • Dedicated zones in the warehouse

  • Extra packing steps

  • Different routing rules

Best Practices – When You Have a Strong System Like Fastcoo

  1. Design your warehouse around system flows, not the other way around.

  2. Let Fastcoo drive waves, queues, and routes; don’t rely on paper.

  3. Tie sortation rules directly to KPIs (cost per order, lead time, error rate).

  4. Model peak-season scenarios inside the system before reality hits.

  5. Keep operators flexible, but keep decisions in the software.

 

Everything we described about warehouse sorting:

  • Isn’t theoretical.

  • It’s how a unified logistics stack like Diggipacks + Fastcoo is meant to operate:

    • One platform,

    • Multiple services (Fulfillment, Last Mile, SaaS, LaaS),

    • With sortation logic embedded at every step of the flow.