Put to Light

Efficient Stock Replenishment

A put to light system is similar to a pick to light system, only instead of picking product to ship to consumers, it is designed to replenish stock to a store. Like pick to light, put to light systems are typically mounted on shelving or carton flow rack with the individual open store shipping boxes placed above or below the designated put to light, visual device. Common configurations have two shelves of 'put' locations within a put to light setup.

Bastian Solutions engineers leverage their in-field experience working with a variety of industries to help inform the best technology selections and configurations. Using a data-backed approach, we can help you decide and integrate on the best picking technology for your operation.


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How Put to Light Works

Hercules-AutoStore-carousel-port-goods-to-person-order-picking-put-to-lightIn a put to light system, containers of individual items are directed to a put to light packing area where each store or order has an assigned packing location in the order consolidation work area. The operator scans the container barcode on an inbound container that may be entering the put to light area from receiving or storage. Once scanned, ‘put’ lights at the ‘put’ locations illuminate and display the quantity to place.

Once the correct item quantity is placed into the shipping container, the operator confirms the ‘put’ by pressing a light or button. The operator repeats these steps by for all locations with an illuminated display, until complete and then moves on to the next product that needs to be put into shipping containers. Put quantities can be any unit of measure that is less than a case, such as eaches or inner packs.

A single put to light device can be used for two locations, which is common in retail distribution layouts.


Bastian Solutions’ Exacta intralogistics software tracks all item quantities put into each shipping container, as well as remaining puts to be completed from the original container, and the remaining quantity in the original container.

Based on business rules and the put to light device used, operators might also have the ability to short a put to a container or split a put across multiple containers for the store or order. Other features within put to light communication include:

  • Closing containers
  • Indication of a full container to close
  • Opening a new container
  • Configurable scan verification as you open a container for the location

If integrated with the Exacta WCS (warehouse control system) routing module, inbound item containers can be dynamically routed to lanes based on workload. Based on how full a lane the inbound container can be routed to a different lane to help balance the work to keep all put operators busy.

Features & Benefits

  • Utilizes the same hardware devices and software technology as used for pick to light
  • Improved replenishment and fulfillment accuracy rates, 99.5% accuracy
  • Faster order cycle times
  • Quick implementation and minimal operator training time
  • Reduced labor costs
  • Paper-less fulfillment option


When considering automating your warehouse order picking process and evaluating various technology options it’s important to consider the following:

  • Product and workflow
  • Labor availability
  • Current and desired throughput rates
  • Other integrated automated technologies like conveyor or goods to person
  • Current software systems – WES, WMS, WCS

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