Push Tray Sorters

Accurate and affordable sorting for a wide variety of shapes and weights

Push tray sorters are a high-speed, continuous-loop sortation conveyor that uses a bar to physically push items off of individual trays. This mechanism allows push tray sorters to reliably handle a variety of product shapes and sizes – polybags, cartons, apparel, even odd-shaped and difficult to convey items – on the same sorter, at the same time.

Push tray sorters are a reliable, cost-efficient, and space-saving alternative to cross belt and tilt tray sorters. Bastian Solutions, as independent integrators, can help you find the right sortation system to meet your unique needs.


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Optisort push tray sorter

How Push Tray Sorters Work

Push tray sorters will simultaneously sort a variety of products ranging from lightweight polybags to irregularly shaped or hard to convey products, even larger cartons and boxes. No matter the size, shape, or material, a push bar gently pushes each item off the tray and into the correct discharge zone. Sortation rates with twin push tray sorters can exceed 13,000 trays per hour.

Push tray sorters are generally comprised of:

  • Continuous loop of sortation conveyor
  • A bar to physically push items
  • Option for twin push tray sorters

Features & Benefits

  • Handles varying package sizes, types, and weights
  • Design provides a lower cost solution to reduce total system investment
  • Flexible layout and modular design allow for inclines, declines, and unlimited lengths
  • Patented discharge mechanism allows relatively small discharge zone and smaller footprint
  • Twin push tray sorter doubles available throughput


Push tray sorter rates vary from about 7,500 trays per hour for single push tray sorters to 15,000 trays per hour for double push tray sorters.

Their ability to handle a wide range of product shapes and sizes, makes them applicable in a variety of industries. Often they are leveraged to handle:

  • Media – books, CDs/DVDs
  • Polybags, boxes, cartons, totes
  • Smaller parcels
  • Pieces (each)
  • Irregularly shaped or hard-to-transport items


Bastian Solutions’ experts will work with you to explore potential turnkey or custom options. Consider the following details when exploring push tray sortation solutions:

  • Type, size and weight of items being sorted
  • Product handling needs
  • Desired throughput rate
  • Facility layout and allotted space

See More Sortation & Conveyor Solutions


Sortation Systems


Conveyor Systems

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