How high-speed singulation reduces labor and increases throughput

The global e-commerce retail sales are expected to exceed $6 trillion by 2025 (an increase of nearly 7% from 2024) and with next-day and same-day delivery becoming increasingly commonplace, the parcel industry is seeking automated solutions not only to boost throughput and productivity but also to reduce operational costs. 

One of the first bottlenecks in a parcel operation is transforming the massive amount of packages in a bulk stream and singulating and spacing them into a uniform line on a conveyor so they can be scanned and sorted downstream. While operations in the past have used diverters, wheel sorters, and even robotics to tackle this challenge, the Körber Business Area Supply Chain research and development (R&D) team combined modularity, flexibility, and artificial intelligence (AI) to create a singulation solution called the Visicon.

In this interview, Alex Scholes (Head of R&D, Business Area Supply Chain North America) and Austin Percifull (Key Account Manager, Parcel Logistics North America) provide an inside look at the parcel industry, its challenges, and what makes the Visicon unique and how Körber’s Innovation Center in Dallas brings that innovation to life.

What do you see as the current challenges that the parcel industry is facing?

Alex:
We are seeing pressure from every direction. Speed, volume, diverse parcel types, labor shortages, and global trade uncertainty are all converging at once. The market has changed fundamentally. Parcel flows are no longer predictable or uniform. Today’s systems must handle everything from soft polybags to heavy or irregular items such as tires or engine parts — and do so with precision and reliability around the clock.

Because of this, our customers are no longer just asking for maximum throughput. What they truly want is resilience. They are looking for systems that are robust, easy to operate and maintain, even when skilled labor is limited. They want flexible architecture, seamless integration into their existing systems and operations, and the ability to adapt and grow without starting from scratch. And more than anything, they want a partner who helps them stay ahead of what is coming next.

Austin:
We see that leading parcel operators want partners who can act fast, offer alternative manufacturing routes and reduce manual inputs wherever possible. If we can reduce manual touches or simplify and automate a process, the customer sees the benefit right away. It’s often the fastest path to measurable ROI [Return On Investment] and improved system efficiency. With Körber’s international footprint and our focus on automation and predictive maintenance, we’re helping them stay ahead.

As the head of R&D in North America, how do you approach solutions to help customers stay ahead of these challenges?

Alex:
We’re not just providing equipment, we’re committed to building agile, end-to-end ecosystems and delivering a broad range of solutions tailored to meet the demands of today’s complex supply chains. One of our key strengths is that we combine software, hardware and integration under one roof, which allows us to move fast and stay in full control. But we’re also pragmatic: we’re vendor agnostic, and if a third-party solution fits better, we integrate it. In R&D, our focus is always on building flexible, future-ready ecosystems. 

Austin:
What our customers appreciate is our hands-on, collaborative approach — working closely to understand their operations and build the right solution together. We bring everything to the table: equipment, integration, service, and a clear long-term roadmap. It’s not about pushing a standard system — it’s about co-creating something smarter, something that truly fits.

What makes the Visicon  and Visicon Compact stand out in the market?

Alex:
What really sets the Visicon apart is its performance and intelligence. It’s currently the fastest singulation system on the market, with a nominal throughput of up to 18,000 parcels per hour. But speed alone isn’t the full story, Visicon combines an AI-based vision system with a matrix of independently controlled conveyor belts. This allows the system to adjust in real time to parcel shape, orientation, and spacing, making it highly accurate even with polybags and irregular formats.

It’s also modular and preassembled, which speeds up installation and makes upgrades easier. And with our software-based Singulator 360, we’re moving into predictive maintenance, giving operators even more control and foresight. Whether it’s a greenfield or a retrofit project, Visicon delivers precision and scalability in one platform.

Austin:
For our customers, what makes Visicon and 
Visicon Compact stand out is how well they solve real-world problems. Visicon is built for high-volume operations — fast, accurate, and robust. But when space is tight, Visicon Compact delivers similar precision in a much smaller footprint with a nominal throughput of up to 7,000 parcels per hour. It’s perfect for retrofitting in existing sites without compromising on performance.

Visicon Compact is also designed for seamless integration with upstream and downstream modules such as the Delayering Line, Aligner Compact, VarioDetect, VarioRoute, and Gapper Line. These connected modules enhance the system’s overall performance and accuracy, especially in singulation and sortation — making the entire parcel flow more efficient and reliable. 

How do you develop tailored solutions for Körber customers’ logistics issues?

Alex:
We approach every project as a collaboration. At Körber, we don’t just deliver products, we co-develop solutions together with our customers. That means understanding their exact challenges, working alongside them on-site or in our new Innovation Center in Dallas.

Austin:
From my side, it's all about partnership. We’re in constant dialogue with our key accounts and other customers, and when a need emerges, whether it’s a throughput issue or a unique product type, we bring that insight straight to our R&D and engineering teams. Our Innovation Center in Dallas plays a huge role. It’s not just a showroom, it’s a live testbed where we walk through the solution with the customer, validate performance, and fine-tune the system until it fits. That process builds trust and better outcomes. It also accelerates decision-making and reduces risk — customers can see exactly what they’re getting before implementation. That level of transparency creates real value.

Where do you see the market heading in the short and long term, and what are your key insights?

Alex:
Over the past decade, technologies like the crossbelt sorter have revolutionized our industry. But that chapter is closing. We’re now entering a new era — one defined by smarter, simpler warehouse automation. 

I see a high demand for warehouse automation that is not just fast, but flexible, scalable, and intelligent. Automation that adapts intelligently to real-world challenges, not just executes predefined tasks, is simple to deploy, and easy to operate. That’s where the market is moving, and that’s exactly where we’re heading. 

Austin:
In the short term, we’re seeing a major shift toward decentralization in the North American parcel logistics market. Mid-sized players are scaling fast, opening smaller and more agile facilities that expand local reach and speed. That shift isn’t a niche development, it’s reshaping the competitive landscape. And it’s driving clear demand for compact, high-performance systems like the Visicon Compact. These are not just space savers — they’re enablers of fast, scalable warehouse  automation without the burden of major infrastructure overhaul.

Looking ahead, that momentum is only accelerating. The future of shipping is local, fast, and smart.