Abstract: A continuous flow material handling system and method for consolidating articles into article groups, includes a plurality of article sources and a plurality of article destinations. A plurality of article merges and at least one sorter are between the article sources and destinations, with each of the merges having a plurality of queue lanes and a discharge. The at least one sorter has an inbound lane and a plurality of outbound lanes. The merges combine articles from a plurality of queue lanes and discharge to a downstream merge or sorter inbound lane. The article queue lanes of an upstream merge receiving articles from the article sources and the sorter outbound lanes discharging to the article destinations. A control system receives data from a warehouse management system (WMS). The control system activates each group at a merge in a same sequence as the group is released to the material handling system.

Abstract: A continuous flow material handling system and method for consolidating articles into article groups, includes a plurality of article sources and a plurality of article destinations. A plurality of article merges and at least one sorter are between the article sources and destinations, with each of the merges having a plurality of queue lanes and a discharge. The at least one sorter has an inbound lane and a plurality of outbound lanes. The merges combine articles from a plurality of queue lanes and discharge to a downstream merge or sorter inbound lane. The article queue lanes of an upstream merge receiving articles from the article sources and the sorter outbound lanes discharging to the article destinations. A control system receives data from a warehouse management system (WMS). The control system activates each group at a merge in a same sequence as the group is released to the material handling system.