Who is Aegis Sortation and what do you do?

Aegis Sortation is an innovation engine in parcel automation. We design and deliver next-generation sortation and conveyance systems that help logistics leaders move faster, smarter, and more efficiently. Our solutions—like SmartSort and Automated Smalls Bagging—are purpose-built to maximize throughput, reduce labor costs, and scale with your growth. Headquartered in Louisville, KY, we serve carriers, 3PLs, and e-commerce operations across North America.

What industries does Aegis serve?

We partner with organizations in parcel, freight, e-commerce, and distribution. Our systems are engineered for high-volume environments where speed, flexibility, and uptime are critical. Whether you’re a global carrier or a regional fulfillment center, Aegis solutions adapt to your operational needs.

Where is Aegis Sortation headquartered and do you operate globally?

Aegis Sortation is headquartered in Louisville, Kentucky. We currently deploy systems across North America and collaborate with global logistics leaders to support international operations.

What is SmartSort and how does it improve parcel handling?

SmartSort is our next-generation steerable wheel sorter designed for the pace of modern logistics. It delivers high-speed sorting—up to 400 feet per minute—with bidirectional diverting and modular 1x4 design for rapid deployment. Fully electric and gearless, SmartSort reduces maintenance costs, eliminates compressed air, and operates quietly under 72 dBA. Its predictive diagnostics and swappable modules keep uptime high and total cost of ownership low.

How does SmartSort differ from traditional sortation systems?

SmartSort offers unmatched flexibility for irregular and soft packages. Unlike traditional systems that struggle with non-conveyables, SmartSort’s progressive divert and bidirectional merge capabilities handle complex parcel mixes with precision. Its modular design enables fast deployment and layout adaptability, making it ideal for facilities facing space constraints or seasonal volume spikes.

What is Automated Smalls Bagging (ASB) and what problems does it solve?

ASB is an end-to-end automation solution for small parcels. It integrates sortation, containerization, and bagging to reduce manual labor by over 50%, cut mis-sort rates, and accelerate throughput. ASB pairs with SmartDock and SmartBagger systems to deliver a seamless, queued workflow—ideal for e-commerce and postal operations where speed and accuracy drive profitability.

Can Aegis systems handle irregular or oversized parcels?

Yes. Our patented progressive divert technology and modular designs allow SmartSort and VersaSort systems to manage irregular shapes, polybags, and oversized items without compromising speed or accuracy.

How do Aegis systems integrate with existing WMS or ERP platforms?

Aegis solutions are designed for seamless integration. Our systems support standard communication protocols and offer API connectivity for real-time data exchange with WMS and ERP platforms. This ensures synchronized operations, accurate tracking, and optimized workflows.

What throughput rates can your sortation systems achieve?

SmartSort delivers speeds up to 400 feet per minute, enabling high parcel-per-hour performance even in peak conditions. SmartBagger achieves up to 180 bags per hour. All of our technologies deliver unparalleled performance and throughput.

What are the maintenance requirements for Aegis solutions?

Our systems are engineered for uptime. SmartSort’s gearless, beltless design minimizes wear and tear, while predictive maintenance tools and real-time diagnostics reduce unplanned downtime. Swappable modules and common components simplify service and keep costs low.

How much labor cost savings can automation deliver?

Customers typically see labor reductions of 30–50% by automating sortation and bagging processes. ASB alone can cut manual handling costs by over 50% while improving accuracy and throughput.

How do Aegis systems help reduce energy consumption and improve sustainability?

Our technologies are energy efficient and sustainable. Products like SmartSort do not require pneumatic power, optimizing efficiency and footprint.

What is the typical implementation timeline for a sortation system?

Most installations can be completed faster than our competitors thanks to our modular design, pre-installation capabilities, and pre-engineered components. Timelines depend on facility complexity and integration requirements.

Does Aegis provide training and ongoing support?

Absolutely. We offer comprehensive training during commissioning and provide lifecycle services, including 24/7 support, preventive maintenance, and system upgrades.

Why is modular automation critical for modern logistics?

Modular automation allows for quicker installation, easy modifications with minimal impact to your operation, and the ability to employ the same technology across multiple areas of your business.

What role does AI play in parcel sortation today?

AI enhances predictive maintenance, dynamic zone control, and real-time performance analytics. It helps optimize routing, reduce downtime, and improve overall system efficiency.

Your Innovative Automation Partner

From our Louisville headquarters to logistics hubs across North America, Aegis Sortation transforms parcel and distribution automation with proprietary technologies, bespoke solutions, and relentless innovation.

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Engineered to Create Raving Fans

Welcome to Aegis Sortation, where innovation and excellence come together to revolutionize automation technology in the express parcel, e-commerce, warehouse, and distribution industries.

As a U.S.-based leader in parcel and distribution automation, we deliver custom-engineered intralogistics systems that enable you to do more with less.

Leveraging decades of material handling expertise, we craft automated solutions that tackle your toughest challenges and scale seamlessly with your business. From concepting to commissioning, we deliver performance you can count on.

Join us on this journey of innovation. Let’s transform your operations and make you our next raving fan.

Custom Automated Solutions Built for You

Sortation

High-speed sortation systems engineered to maximize parcel flow, accuracy, and uptime

SmartSort steerable wheel sorter table for parcel and distribution industry.

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Conveyors

Durable, scalable conveyor solutions built to move freight faster and smarter

Roller conveyor belt, warehouse and parcel conveyor.

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Custom Equipment

Tailored automation designs that solve complex logistics challenges with precision and innovation

Customized automation equipment and systems for warehousing and parcel industries.

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Customization with the flexibility you need

At Aegis Sortation, we design and manufacture automation systems that flex to your space, scale with your growth, and solve the unique challenges of your operation. Whether you're integrating robotics, conveyors, or specialized sortation modules, our expert team delivers intuitive, high-uptime solutions built around your goals.

Our customers drive everything we do. From discovery to deployment, we collaborate closely to understand your needs and engineer systems that perform with precision.

Connect with us today and let Aegis transform your complex technical equipment into perfectly synced automated systems that streamline your operations.

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Service You Can Count On

Our turnkey systems integration, lifecycle services, and expert support help streamline implementation and operation so you can focus on what matters most.

Seamless integration delivering a full range of automated solutions, including AS/RS, AGVs, robotics, and IoT.es here

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Comprehensive maintenance, parts support, and consulting to keep you running at peak performance.

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Hands-on instruction to empower your teams and ensure successful implementation from day one.

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Discover More Insights

Stay ahead with fresh perspectives on automation, sortation, and systems innovation. Check out our latest blog posts and resources designed to help you make smarter decisions.

Blog

Nov 14, 2025

The Role of Digital Twins in Optimizing Automated Distribution Centers

Nov 14, 2025

Discover how Digital Twins revolutionize automated distribution centers by boosting real-time decision-making, enabling seamless integration, and increasing efficiency. Learn why this tech is the future of logistics and engineering practices.

Nov 14, 2025

Nov 10, 2025

AI in Last-Mile Delivery: The New Frontier for Speed, Security, and Efficiency

Nov 10, 2025

Discover how artificial intelligence (AI) and automated solutions are revolutionizing last-mile delivery in e-commerce and parcel logistics. From AI-powered route optimization and autonomous drone delivery to advanced theft prevention systems, learn how leading logistics teams are leveraging real-time data and machine learning to boost speed, accuracy, and customer satisfaction.

Nov 10, 2025

Oct 30, 2025

What Is SmartSort? A Deep Dive into Steerable Wheel Sortation Technology

Oct 30, 2025

Discover how SmartSort is redefining parcel automation. From high-speed sorting to modular design, this deep dive into steerable wheel technology reveals how one intelligent platform can streamline operations, reduce mis-sorts, and future-proof your facility.

Oct 30, 2025

Oct 20, 2025

What is Sortation? The Unsung Hero of Parcel and Distribution Logistics

Oct 20, 2025

Sortation is more than a step in parcel handling—it’s the engine behind speed and accuracy. From inbound receiving to outbound dispatch, discover how sortation shapes every stage of operations and why it’s critical for on-time delivery. Learn how smarter systems turn logistics into a competitive advantage.

Oct 20, 2025

Oct 16, 2025

Press Release: Aegis Unveils New SmartSort Steerable Wheel Sorter Built for Speed and Flexibility

Oct 16, 2025

Aegis Sortation has introduces SmartSort, a fully electric steerable wheel sorter built for speed and flexibility in modern logistics. With modular design, high-speed performance up to 400 feet per minute, and reduced maintenance through a gearless, beltless system, SmartSort delivers precision and uptime.

Oct 16, 2025

Oct 7, 2025

Building Resilient Supply Chains: The Role of Automation in Peak Season Preparedness

Oct 7, 2025

Struggling with peak season chaos? Discover how modular automation turns pressure into performance by boosting speed, accuracy, and resilience in parcel fulfillment.

Oct 7, 2025

Oct 6, 2025

The High Cost of Mis-Sorts: What Every Logistics Operation Needs to Know

Oct 6, 2025

Mis-sorts are draining your logistics operation—costing time, money, and customer trust. Discover how sorting errors happen, why it's important to address the root cause, and how SmartSort’s precision technology helps eliminate mis-sorts at the source.

Oct 6, 2025

Sep 25, 2025

Designing for Flexibility: How Modular Automation Supports Your Evolving Business

Sep 25, 2025

Unlock the power of modular automation—discover how flexible systems from Aegis Sortation help logistics teams adapt, optimize, and stay ahead in a fast-changing world; future-proof your operations with solutions built for bold moves and seamless growth.

Sep 25, 2025

From Manual to Automated: Overcoming the Top Challenges in Parcel Sortation

Sep 25, 2025

Manual sortation has powered the parcel industry for decades; now, automation is redefining what’s possible. Discover how Aegis Sortation helps operators overcome accuracy, efficiency, and growth challenges by putting people and technology side by side.

Sep 25, 2025