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Pick to Light for distribution and wholesale: thousands of SKUs, zone and batch picking

In distribution and wholesale, Pick to Light lights up every location in a warehouse zone that needs picking, with quantities, and the picker simply takes and confirms each one. Searching among thousands of SKUs disappears, zones work in parallel and the range can be re-slotted in software. We have developed the system since 2018 and adapt it to the racking you already have.

At a glance

  • Zones work in parallel, orders move between them
  • Re-slotting in minutes, not days
  • Retrofit onto your existing racking

Thousands of items and tight cut-off times

A distribution warehouse has a wide range, orders with dozens of lines and fixed truck departure times. Pickers spend much of the shift searching for locations and checking codes, errors appear with similar packaging and throughput is hard to plan. When the range changes seasonally, relabelling locations and retraining people takes days.

Pick to Light for distribution and wholesale: thousands of SKUs, zone and batch picking

What Pick to Light brings to a distribution centre

Zone picking

Each picker covers a zone and sees only the lit locations for the current order. The tote then moves on to the next zone.

Batches on carts and walls

Small customer orders can be batch-picked onto a cart with LED positions, or picked in bulk and split at a put wall by store or route.

Software-defined locations

With LED strips in profiles, you reassign locations, resize zones or add SKUs in the system. A seasonal layout change takes minutes.

Performance visible in real time

Every confirmation is a data point. Shift leaders see order progress and individual performance and can move people between zones in time.

How it works

  1. 1The WMS releases orders by route and departure time.
  2. 2The order tote enters the first zone and is scanned.
  3. 3All locations for that order light up in the zone, with quantities.
  4. 4The picker takes and confirms; a dark zone means the zone is done.
  5. 5The tote moves to the next zone or to shipping, with status updated in the WMS.

WMS and ERP integration

Pick to Light connects to your WMS or ERP via REST API, MQTT or WebSocket, and we provide a test environment for integration work. For wholesalers without a warehouse system we offer Logisio WMS, which manages zones, waves and batches. And if your IT team expects the integration to be complicated, we can do it for them or show them exactly how.

Software

What to prepare for an inquiry

  • Number of SKUs and their split by velocity
  • Orders and order lines per day
  • Warehouse layout and rack types
  • Order cut-off and truck departure times
  • The WMS or ERP you use

Recommended products

Pick to Light Carts

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Pick to Light Shelves

Stationary workstation with fast access to thousands of positions

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Pick to Light Sortwall

Order sorting with maximum accuracy and speed

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Frequently asked questions

Not always. It pays off most in zones with fast-moving items and many picks, where every second saved is multiplied. Slow movers or bulky goods can stay with another method. We recommend starting with a velocity analysis and a pilot zone, measuring results and only then deciding where to expand.

The system supports multi-operator work with colour coding, and each person sees only their own instructions. With LED strips in aluminium profiles, up to 8 operators can work at one station. At peak you can add people to a busy zone without changing the layout or risking that someone picks another person's task.

LED strips in profiles have no moving parts or mechanical switches. One failed light does not stop the whole rack, and any replacement takes a technician minutes without tools. Profiles and LED strips carry a 3-year warranty. Support is available remotely and on site, and our team responds quickly.

Yes, and we recommend it. A pilot at one workstation or in one zone usually takes 2–4 weeks. You see results on your own data before committing to the whole warehouse. The system is modular, so further zones are added without touching the part already running, and the WMS integration stays the same.

Other applications

All applications

Shall we look at your operation?

Send us your number of locations, orders and shifts – we will propose a setup and a payback estimate.

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