The Advanced Hybrid Station handles eaches, cases, and full pallets in a single order — with a single worker. Not the fastest at any one format. The only station that covers all of them without splitting your labor.
Unit Types, One Station
Operator Per Station
Units Per Hour
Deployment
PrimeOS Orchestration
Most DCs route eaches, cases, and full pallets through separate systems. That means separate labor pools, separate staging logic, and separate software handoffs — all to fulfill a single mixed order. When your order mix shifts, none of those systems can cover for each other.
Separate operators for separate unit types means your staffing doesn’t flex with your order profile. You’re paying for peak each-pick headcount on days when 60% of the floor is handling cases.
Manual staging between pick paths creates timing bottlenecks invisible to your WMS. Orders sit complete on one path waiting for the others before they can ship — every time.
A single-format station can’t adapt when your order mix shifts. A surge in each orders buries a case-pick line. A new retail customer with mixed pallets lands in no-man’s land.
The Advanced Hybrid Station is the only pick station that handles all three unit types simultaneously. PES routes each unit to the station in the right sequence — eaches pulled from shelf positions, cases broken from pallets, full pallets passed through directly — and the operator builds the order without switching systems, zones, or workflows.
Two form factors: MobileShelf-style shelf positions for loose eaches, and pallet-footprint bays for case and full-pallet picks. One station footprint. One operator headcount.
PES sequences inbound product to the station based on what each active order needs — not what the station is configured for. The station adapts. The operator doesn’t.
Loose units delivered by MobileShelf AMR. Shelf positions bring product to the operator — no travel, no dead time. Vision confirms every unit picked
Full cases broken from single-SKU inbound pallets. MobilePallet AMR delivers the source pallet; vacuum gantry assists heavy case lifts.
Full-pallet pass-through when the order calls for it. MobilePallet AMR positions the source pallet; it routes to the output lane without operator handling.
Mixed orders don’t all ship the same way. PES tracks every unit’s destination from pick to dock — building totes, pallets, and mixed loads simultaneously on a single order profile without manual consolidation.
Eaches and small cases route into totes for retail replenishment or parcel ship. PES counts and confirms every unit placed.
Multiple SKUs build to a single pallet per order. PES clusters picks by destination — inbound single-SKU, outbound mixed-SKU by design.
Mixed shipments with both pallet layers and carton adds build simultaneously. No second-pass consolidation, no staging queue.
PES doesn’t think in orders — it thinks in SKUs. Every inbound order decomposes to individual pick-level tasks, and identical SKUs across multiple active orders cluster into a single pick run. The operator touches a location once to satisfy multiple orders simultaneously. Every unit is tagged to its destination order and output pallet as it’s picked.
Single-SKU per pallet
Apple Sauce 24ct
Fruit Cups 12ct
Juice 6pk
Snack Mix 18ct
Order → SKU decomposition
Mixed-SKU per pallet
One location touch. Multiple orders satisfied. When SKU A appears in Orders 1, 2, and 4, PES sends the operator to that location once — picking the combined quantity needed across all three and routing each unit to its destination pallet automatically. Compared to order-by-order picking, this collapses location visits and raises effective throughput without changing a single piece of station hardware.
The Hybrid Station doesn’t operate in isolation. PES orchestrates the full robot fleet — MobilePallet AMRs delivering case and pallet product, MobileShelf AMRs delivering each-pick positions — all sequenced to the station without operator coordination overhead.
MobilePallet AMRs pull source pallets from reserve storage and position them at the station. No forklift coordination. PES sequences delivery to match the active pick list in real time.
MobileShelf AMRs bring shelf positions to the station for each-pick tasks within the same order cycle. The operator never travels — product arrives in sequence.
PES coordinates both robot fleets to the same station simultaneously — interleaving case picks, each picks, and full-pallet pass-throughs within a single order build cycle without manual handoffs.
Peak rate is easy to demonstrate. Sustained rate through hour 7 of a shift is what matters in production. The Hybrid Station is built for both — through vacuum assist, scan-every-unit vision, and zero operator travel.
225–250 units per hour is a realistic baseline for a balanced order profile. Actual rate varies with pick mix — case picks from pallets run faster than each picks from shelf positions — so your number depends on what your orders actually look like.
Overhead vacuum arm handles heavy case picks — removing the physical fatigue that degrades throughput in the back half of a shift. Operator guides, not lifts.
Vision system confirms pick accuracy on every unit without a hand-scan step. Zero missed scans. Zero audit rework at the dock. Throughput stays clean at speed.
The operator never leaves the station. Robots deliver product in pick sequence. Travel is the first thing that kills sustained throughput — PES eliminates it entirely.
When your order profile is all eaches and you need 300+ picks per hour without fixed infrastructure.
Outbound mixed-SKU pallets built at 400–600 CPH with Bullseye Scheduling and robotic arm + PES orchestration.
The unified platform orchestrating every robot, every order, every pick — PES execution engine included.
Tell us about your order profile — eaches, cases, pallets, or all three — and we’ll show you how the Hybrid Station covers it with a single FTE and PES orchestration.
Denver-based team. Typical response within 1 business day.
