Pick-to-light flow racks combine gravity-fed bin and carton lanes with integrated PTL bar mounting hardware — delivering directed picking with lane-level LED confirmation in high-mix, error-sensitive assembly and kitting environments. T-slot frames accept standard PTL bar systems from all major vendors without drilling or secondary mounting structures.
T-slot channels accept standard PTL bar mounting brackets from SSI Schäfer, Honeywell, and other major PTL vendors — no drilling or secondary rails required.
Each lane has an individual LED indicator light-up on the active pick — illuminated lane draws the operator's eye to the correct pick position without reading labels.
PTL displays above each lane show the pick quantity for the current kit or assembly sequence — operator confirms pick quantity before extinguishing the light.
Touch-confirm buttons on each lane bracket acknowledge the pick — system records pick completion without barcode scanning.
PTL bar data connects to WMS, WCS, and production control systems via standard Ethernet — pick sequences driven by production orders in real time.
Inclined bin and carton lanes maintain continuous FIFO component supply to the PTL pick face — components always available at the illuminated lane.
PTL-directed kitting for high-mix BOMs — operators follow light sequence to build accurate kits at high throughput without memorising part locations.
PTL confirmation at every assembly pick — no component can be missed or doubled without triggering a pick error alert before the next unit starts.
PTL-directed each-pick in distribution centers — pick accuracy above 99.99% for B2C and B2B order fulfilment without barcode scanning.
PTL confirmation for PCB assembly component picks — every lane pick confirmed before kit complete signal enables tray advance.
PTL-directed pharmaceutical kit assembly with pick confirmation records — full electronic audit trail for GMP compliance without paper travellers.
PTL directs kitters to correct components for each vehicle variant in a mixed model sequence — zero variant confusion without part number reading.
PTL pick records provide full electronic assembly audit trail for medical device regulatory submissions — each pick recorded with timestamp and operator ID.
PTL-directed repair kit assembly for RMA operations — correct parts for each repair type directed by PTL from the repair work order.
Modular Solutions rack frames are designed with T-slot channels that accept mounting brackets from all major PTL vendors including SSI Schäfer, Honeywell Intelligrated, Knapp, Vanderlande, and others. Vendor-specific bracket designs are provided by Modular Solutions for each PTL system. Custom brackets for other vendors are available on request.
Modular Solutions supplies the rack frame with PTL mounting hardware. PTL controllers, displays, and confirmation buttons are supplied by the PTL vendor or the customer's system integrator. Modular Solutions coordinates with the integrator to ensure bracket positioning and cable routing are engineered into the rack design.
Cable management extrusions route PTL bus cables along the T-slot frame uprights and horizontal beams — cables protected inside the extrusion channel, not exposed externally. Power entry and Ethernet connection points are positioned at the top rear of the frame for clean cable routing to overhead cable trays.
Yes. PTL mounting brackets and cable management extrusions are available as retrofit kits for existing T-slot flow racks. The retrofit does not require frame disassembly — brackets slide into existing T-slot channels. Cable routing channels add to the existing uprights with standard T-slot hardware.
PTL-directed picking with confirmation achieves pick accuracy rates of 99.95–99.99% in standard kitting and distribution operations. The primary error reduction comes from directing the operator to the exact lane (eliminating location errors) and requiring quantity confirmation before the light extinguishes (eliminating quantity errors).
Yes. Multi-operator PTL configurations assign pick zones to operators — each operator has a dedicated zone on the rack face with independent PTL light sequences. Zone boundaries are defined in the PTL controller and can be dynamically reassigned based on staffing levels and throughput targets.
Request a quote or contact our engineering team to discuss your pick-to-light flow racks requirements.