Optimizing Warehouse Operations with a Pick to Light System
Challenges
Modern warehouses face increasing pressure to deliver faster service, minimize picking mistakes, and enhance overall efficiency. Traditional manual picking processes are:
✔️ Time-consuming – Workers spend significant time searching for items
✔️ Error-prone – Incorrect picks lead to returns and customer dissatisfaction
✔️ Training-intensive – new workers require extensive ramp-up time
A mid-to-large warehouse operator needed a solution to streamline order picking without complex wiring or costly infrastructure overhauls.
Solution: StackIOT Wireless Pick to Light System
StackIOT Technologies introduced an innovative Bluetooth Low Energy (BLE) Pick to Light (PTL) System designed to automate and accelerate order fulfillment.
System Components
- PTL Tags – Wireless e-paper display tags with LED, push button, and built-in battery. No external power or wiring required.
- PTL Gateway – BLE-enabled gateway connecting tags to the server; one gateway covers 15–20 meters.
- PTL Server – Central application server managing all tags, gateways, and real-time event processing.
How It Works
- Task Creation
Operator creates a picking task on the PTL Server web application. - Gateway Routing
Server identifies the closest gateway to the target PTL Tag. - Visual Guidance
Gateway updates the tag display, and the LED begins flashing, guiding the worker directly to the correct bin. - Pick Confirmation
Worker picks the item and presses the button on the PTL Tag. - Real-Time Update
Confirmation is instantly sent back to the server via the gateway for real-time tracking and inventory updates.
Key Specifications
✔️Display: 2.9" e-paper (296×128 pixels), 180° viewing angle, ultra-low power
✔️ Connectivity: Bluetooth 5.0+, range up to 50m (line of sight)
✔️ Battery Life: Up to 2–3 years on standard AAA or coin cell batteries
✔️ Power Management: Intelligent sleep mode during inactivity
Results & Benefits
| Metric | Improvement |
|---|---|
| Picking Speed | Up to 50% faster — no time wasted searching |
| Picking Accuracy | Near 100% — visual guidance eliminates guesswork |
| Worker Training Time | Reduced by over 70% — intuitive LED/button interface |
| System Deployment | Days instead of weeks — no wiring required |
| Maintenance Cost | Minimal — 2–3 year battery life, no cables |
Additional Advantages
✔️Fully Wireless – Deploy faster, flexibly, and cost-effectively
✔️ Scalable – Easily add more tags or gateways as operations grow
✔️Energy Efficient – E-paper and BLE 5.0 ensure ultra-low power consumption
✔️Real-time Visibility – Instant confirmation and status updates
Ideal Use Cases
✔️ Distribution centers
✔️ Assembly lines
✔️ High-volume order fulfillment warehouses
✔️ E-commerce and retail logistics
Conclusion
The StackIOT Radio Interoperability System successfully bridged the gap between legacy radio communication infrastructure and modern IP-based The StackIOT Pick to Light System demonstrates how smart, energy-efficient, real- time communication can make modern warehouse operations smarter, faster, and more reliable. By eliminating wiring complexity and leveraging BLE + e-paper technology, StackIOT delivers a practical, scalable automation solution for today's demanding logistics environments.