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HyperSort in Action: Automated Returns Processing for a Cosmetics 3PL Operation
HyperSort in Action: Automated Returns Processing for a Cosmetics 3PL Operation
2026-07-29
HyperLeaphttps://www.youtube.com/embed/wY6myeCjTi0?si=QpSGscVaBJHu_Qit" title="YouTube video player
Overview
A 3PL warehouse handling outbound delivery and returns for a cosmetics brand deployed HyperLeap's HyperSort Vertical Sorting System to automate its daily returns processing workflow. The facility handles a varied product mix including sheet face masks, product samples and fragile glass bottles - items that require consistent, accurate handling throughout the sortation process.
Challenge
With over 3,400 returned units arriving daily, the warehouse relied on three members of staff sorting across multiple shifts. The diversity of the product range - combined with the fragility of many items - resulted in a sorting error rate above 5%, creating downstream quality issues and ongoing operational pressure.
The facility required a solution capable of handling high daily volumes accurately, reducing manual labor dependency, and accommodating a wide range of product formats without structural modifications.
Solution
HyperLeap deployed a HyperSort Vertical Sorting System within a footprint of approximately 73m²:
- 1 Standard Loading Station
- 6 HyperBot Sorting Robots
- HyperWall × 4, covering 160 sorting destinations
- 4 sorting induction stations
Results
- 3,400 ppd returns sorting capacity at 100% accuracy
- Labor reduced from 3 to 2 operators
- 3× efficiency improvement
- ROI achieved in under one year
- Scalable configuration for future volume growth
Interested in how HyperSort could support your returns processing or 3PL operation?
Get in touch with our team → mail to sales@hyperleap.com.cn
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