Reliable out of gauge systems with increased functionality


UK independent parcel carrier Yodel, required a new automated sortation area in response to the increasing demand on Out of Gauge (OOG) product sortation.

Bulky, out of gauge, non-machinable or ‘ugly traffic’ shaped items, such as flat pack furniture, car exhausts and ironing boards, which usually require manual handling, account for 5% of the market by value (according to Apex Insight).

The process of sorting by hand slows down the transit of goods through the network, therefore reducing the number of parcels that can be sorted in peak periods and increases the risk of damages and mis sorts due to human error.

Yodel required a solution which would deliver improvements in flow as well as reduce parcel handling by colleagues.


A dynamic and bespoke conveyance solution was implemented by Breathe Technologies to ensure Yodel can handle a wide range of products within a small footprint.  The solution utilises Intralox sortation equipment, consisting of Activated Roller Belt technology, providing gentle and precise sorting of items which historically would go through a manual process.

The new system, costing over £1 million, replaces existing infrastructure of two manual sorting carousels.  It can handle items up to 1.8m long and up to 0.9m wide.


A sortation system that

  • Can handle items up to 1.8m long and up to 0.9m wide
  • Process up to 2,500 metre-long items per hour
  • Reduce manual handling rates by 75% with automatic scanning, weighing, volumizing and photography prior to sorting to Yodels nationwide network of customer delivery depots.