**Quick Answer: The OPEX Sure Sort® is an automated robotic sorting system that uses self-charging iBOT® robots to sort up to 2,400 items per hour in a compact footprint. It requires minimal labour, can be installed in as little as three days, and one system can replace up to six traditional put walls. Smarter Automated Solutions is OPEX’s exclusive Australian partner.

If your warehouse team is still manually sorting items into orders, or relying on outdated put-wall systems that bottleneck throughput, you’re leaving efficiency on the table. As e-commerce volumes surge and customer expectations tighten, the pressure on distribution centres to sort faster, more accurately, and with fewer people has never been greater. This guide covers everything you need to know about the OPEX Sure Sort®: how the technology works, what it costs to justify, real-world Australian results, and how to determine if it’s the right fit for your operation.

What Is the OPEX Sure Sort®?

The OPEX Sure Sort® is a fully automated robotic sorting system designed for order consolidation, batch pick sorting, and returns processing in distribution centres. It uses OPEX’s proprietary iBOT® autonomous delivery vehicles to replace manual sorting workflows, delivering enterprise-level throughput in a compact footprint.

Unlike traditional conveyor systems that require large footprints and complex infrastructure, the Sure Sort is modular, scalable, and can be installed in as little as three days. It is suited to mid-size and large operations across e-commerce, apparel, 3PL, and returns processing.

How Does the OPEX Sure Sort® Work?

The Sure Sort works by inducting items onto a conveyor, scanning and measuring each one, then dispatching autonomous iBOT robots to carry items to the correct destination bin. The process requires minimal labour compared with manual sorting.

Here is the step-by-step sorting process:

Induction: Items enter the system via a conveyor induction module. The system scans each item, measures its dimensions (maximum 15.24 cm item height, 7.62 cm gap between items), and assigns it a destination bin.
Routing: An iBOT receives real-time routing instructions and navigates the enclosed grid to deliver the item. iBOTs can update their destination mid-route, dynamically optimising throughput as conditions change.
Delivery: A drop conveyor accelerates items for precise delivery.
Pack notification: When an order is complete, the pack-to-light system illuminates an LED indicator at the relevant bin, signalling staff that the order is ready for packing and despatch.

How Do iBOT Robots Recharge?

iBOT robots are self-charging using ultra-capacitor technology that captures energy during braking, meaning they recharge continuously during normal operation. There are no manual battery swaps, no scheduled downtime, and no charging stations to manage. This is a key differentiator from competing robotic sorting systems that require battery replacement or docking cycles.

What Are the OPEX Sure Sort® Specifications?

Maximum throughput: Up to 2,400 units per hour (UPH)
Item weight (standard): Up to 2.27 kg
Item weight (Sure Sort® X): Up to 9 kg
Maximum item height at induction: 15.24 cm
System length: 1.55 m up to 13.96 m
System width: 3.35 m at the input conveyor
System height: 2.72 m
Installation time: As little as three days
Environmental range: Ambient and chilled environments
Scalability: Add iBOTs to increase throughput

The modular architecture means the system ships in configurable, stackable units that can be installed and commissioned significantly faster than traditional sortation infrastructure, and expanded incrementally as volume grows.

What Industries Use the OPEX Sure Sort®?

The Sure Sort is used across e-commerce fulfilment, apparel and fashion, third-party logistics (3PL), returns processing, and health and beauty distribution. Any operation with high SKU variety, high daily order volumes, or labour-intensive manual sorting is a strong candidate.

E-Commerce Fulfilment

High SKU variety, unpredictable volumes, and same-day/next-day despatch requirements make e-commerce one of the most demanding environments for manual sorting. The Sure Sort automates order consolidation from batch picks across hundreds of SKUs simultaneously.

Apparel and Fashion

Apparel DCs contend with enormous SKU counts, poly-bagged items, and size/colour/style matrix sorting. The Sure Sort processes up to 2,400 items per hour, a rate manual operations cannot match, while reducing pick errors and labour costs significantly.

Third-Party Logistics (3PL)

3PLs managing multiple client inventory streams benefit from the Sure Sort’s compact footprint and scalable throughput.

Returns Processing

The Sure Sort accelerates returns sorting, reducing backlog and returning stock to sellable inventory faster.

Eyewear, Cosmetics, and Health Products

Smaller, irregularly shaped items that resist easy barcode scanning work well with the Sure Sort’s induction system. It can be paired with RFID scan tunnels for poly-bagged or shrink-wrapped items.

What Results Has the OPEX Sure Sort® Delivered in Australia?

The first OPEX Sure Sort installation in Australia was deployed at NPFulfilment in 2018 by Smarter Automated Solutions. The result: a batch pick and order consolidation process that previously required eight employees now runs with three.

NPFulfilment has since grown to six warehouses across Australia and New Zealand. Their story is one of the most documented examples of warehouse automation success in the ANZ region, demonstrating what is achievable when automation is matched correctly to operational requirements.

OPEX reports that the Sure Sort can deliver payback in as little as two years.

How Does the OPEX Sure Sort® Compare to Manual Sorting?

Metric	Manual Sorting	OPEX Sure Sort®
Throughput	Limited by manual handling	Up to 2,400 UPH
Labour required	Scales with volume	Minimal labour
Error rate	High (human fatigue)	Minimal (automated)

What Is the ROI on the OPEX Sure Sort®?

The Sure Sort delivers ROI through five value drivers: labour cost reduction, error elimination, throughput speed, space efficiency, and rapid deployment. OPEX reports payback in as little as two years.

Labour cost reduction: Up to 2,400 UPH replaces multi-person manual sorting teams, directly reducing your largest operational cost.
Error elimination: Automated sorting removes mispicks and mis-sorts, reducing customer service costs and returns handling.
Throughput speed: Handle peak season, flash sales, and promotional spikes without temporary staff or despatch slowdowns.
Space efficiency: With its compact footprint, the Sure Sort fits facilities that cannot accommodate traditional conveyor sortation.
Rapid deployment: Modular design means installation and commissioning in as little as three days, minimising operational disruption.

Is the OPEX Sure Sort® Right for Your Operation?

The Sure Sort is best suited to operations with high daily order volumes, high SKU variety, labour bottlenecks, or limited floor space. It is particularly strong for 3PLs, e-commerce fulfilment centres, and apparel DCs.

Consider the Sure Sort if your operation meets one or more of these criteria:

High daily order volumes with manual sorting creating bottlenecks
High SKU variety across apparel, e-commerce, or multi-category fulfilment
Need to reduce labour dependency without sacrificing throughput or accuracy
3PL operator seeking to improve cost structure and service levels
Handling returns volume that requires faster processing back to sellable stock
Seasonal or growth-driven volume spikes requiring scalable capacity
Limited floor space that cannot accommodate traditional conveyor infrastructure

Frequently Asked Questions About the OPEX Sure Sort®

What is the OPEX Sure Sort®?

The OPEX Sure Sort® is an automated robotic sorting system that uses self-charging iBOT® robots to sort items into destination bins for order fulfilment. It processes up to 2,400 units per hour in a compact footprint, with minimal labour required.

How fast is the OPEX Sure Sort®?

The Sure Sort sorts up to 2,400 units per hour (UPH).

How much space does the OPEX Sure Sort® require?

A Sure Sort system is 1.55 m up to 13.96 m long, 3.35 m wide at the input conveyor and 2.72 m high, and OPEX says one system can replace up to six traditional put walls. That makes it accessible to mid-size operations and facilities with constrained floor space.

How long does OPEX Sure Sort® installation take?

Due to its modular design, the Sure Sort can be installed and operational in as little as three days. This is significantly faster than traditional automation projects, which often require months of infrastructure work.

How do Sure Sort iBOT robots recharge?

iBOT robots use ultra-capacitor technology to capture energy during braking, recharging continuously during normal operation. No manual battery swaps or charging downtime are required.

What is the OPEX Sure Sort® ROI timeframe?

OPEX reports payback on the Sure Sort in as little as two years, primarily through labour cost reduction, error elimination, and increased throughput capacity.

Who is the OPEX Sure Sort® Australian partner?

Smarter Automated Solutions is OPEX Corporation’s exclusive authorised partner in Australia. They have been deploying Sure Sort systems since 2018, including the first-ever Sure Sort installation in Australia at NPFulfilment.

Can the OPEX Sure Sort® operate in chilled environments?

Yes. The Sure Sort is rated for both ambient and chilled environments, making it suitable for cold-chain fulfilment operations.

What items can the OPEX Sure Sort® sort?

The Sure Sort handles items up to 2.27 kg (standard) or 9 kg (Sure Sort® X), with a maximum item height of 15.24 cm at induction. It accommodates irregular shapes and sizes, and can be paired with RFID scan tunnels for poly-bagged or shrink-wrapped items.

How does the Sure Sort compare to traditional put-walls?

Traditional put-walls require manual labour to sort items into bays. The Sure Sort replaces this with autonomous iBOT robots, and OPEX says one system can replace up to six traditional put walls, with minimal labour and continuous operation without fatigue.

How Smarter Automated Solutions Can Help

Smarter Automated Solutions is an official OPEX integration partner in Australia, with over 80 years of combined industry experience in warehouse automation design, consultancy, project management, and turnkey implementation.

We designed, supplied, and commissioned Australia’s first Sure Sort installation in 2018 and have deployed multiple systems across Australia since then. We work with operations across 3PL, e-commerce, retail distribution, apparel, and health products.

Whether you’re exploring the Sure Sort as a standalone sorting solution or integrating it into a broader automation strategy including goods-to-person systems, conveyor networks, and warehouse control software, our team delivers systems that perform from day one.

Ready to see what the OPEX Sure Sort® could do for your operation?

Contact the Smarter Automated Solutions team to arrange a consultation or live product demonstration.

Smarter Automated Solutions is an official OPEX integration partner in Australia, providing design, supply, and implementation of warehouse automation systems including the Sure Sort®, Perfect Pick® HD, and associated material handling solutions.

What Is the OPEX Sure Sort and How Does It Work? A Guide for Australian Warehouses