One layer from the host to the PLC
Wave or batch release, license-plate and order context, and scan-weigh-dim-label verification — then a handshake the PLC can confirm.
Learn moreSecure Sorter · Electrol Systems, Inc.
Verify every carton.
Divert with confidence.
Secure Sorter is the warehouse control platform behind Electrol's integration work. It verifies scan, weight, size and label, decides the lane, and records what happened — so the line can keep moving without guessing. Motion and safety stay where they belong.
- Fewer mis-sorts — it does not guess a lane
- Faster commissioning, by configuration
- One platform, from the WMS to the PLC
- Clearer operator screens
- Multi-vendor controllers
- TLS 1.3, AES-256-GCM, and Argon2id
How a carton flows
From a released order to a confirmed divert — and a safe way out when the data is not good enough.
Work is released
The warehouse or host system issues work. Orders can be released in a wave or a batch when Electrol configures that policy for the site.
Scan, weigh, dim, label
The carton is identified and measured. Secure Sorter verifies those results before it decides a destination.
A lane is decided
Routing rules assign a lane. The decision is a checked divert request, not a hope that the PLC will just know.
The PLC takes the motion
The controller executes the divert and owns the motors. Secure Sorter does not sit in the motion loop.
The confirm is recorded
A divert confirm comes back. The event, the license plate and the order context are kept for the people who run and audit the line.
Or it takes the fail-safe path
A no-read, late data, missort, lost carton or timeout goes to recirculation or the exception lane. The software does not guess.
What you can actually put to work
Named capabilities from the platform Electrol commissions — not a generic warehouse-software list.
Sortation that confirms, then records
Lane assignment, checked divert logic, divert confirm, recirculation, missort and lost-carton handling, and a fail-safe exception lane.
Learn moreConveyor visibility, motion on the PLC
Line-enable permission and zone status for the people running the line. Motor-driven roller zero-pressure accumulation stays on the cards.
Learn moreScreens designed, not rebuilt from scratch
A drag-and-drop designer in Engineering Studio, a 119-piece conveyor library, original warehouse symbols, and ISA-101 or color looks.
Learn moreTalk to the controllers you already have
Logix EtherNet/IP, Siemens S7, Modbus TCP, OPC UA, MQTT with Sparkplug-style publishing, and other drivers — commissioned per site.
Learn moreSee it, tell someone, keep the history
Tag-limit evaluation, an alarm journal, shelving, and a notification pipeline with escalation — email, webhook or SMS, configured by Electrol.
Learn moreKnow what the line actually did
Tag history, shift and sorter reports in PDF, CSV or a spreadsheet, and a SQL bridge to plant databases.
Learn moreEncryption is a headline strength
HTTPS is TLS 1.3 by default. Secrets, credentials and backups use AES-256-GCM. Passwords are Argon2id. Licenses, images and revocation lists are Ed25519-signed. Fieldbus is not natively encrypted.
Learn moreWhy teams choose Secure Sorter
Differentiators that come from how the software is designed, and from who delivers it.
It refuses to guess
No-read, late data or a failed check goes to the exception lane or a recirculation path. A carton is never given a destination the software cannot stand behind.
The PLC still owns motion
Secure Sorter decides and records. The controller executes and confirms. Safety stays on hardwired circuits. That boundary is a design rule, not a slogan.
Operators get a clearer screen
Views are built in a drag-and-drop designer, bound to tags, and can follow an ISA-101-inspired muted look or Electrol's color palette — chosen with the operations team.
One platform, WMS to PLC
Order release, verification, sortation, operator screens, alarms, historian and drivers live together. Electrol commissions them as one signed project image.
Writes are controlled, and audited
Live writes are an administrator-controlled, audited capability. Safety, motor and PLC-mode commands stay on a blocklist that cannot be turned off. An optional tag allow-list can further limit what may be written.
Built by the integrator
Electrol Systems designs the panel, the PLC program, the conveyor controls and the safety. Secure Sorter is the warehouse control software used in that work — one team, one responsibility.
Before, and after the control layer is in place
A generic picture of the problem this platform is built to solve — not a named competitor, and not a promised percentage.
A typical line, before a control layer like this
- Destination logic buried in one-off PLC and script code that is hard to change on a live line.
- A no-read or a late scan gets a best-guess lane, and a mis-sort is discovered downstream.
- Operator screens rebuilt from scratch for each project, with little shared symbol language.
- Thin history: hard to say which carton went where, who released the work, or when a divert failed.
- Each new controller family or scanner means another custom integration, starting near zero.
- Warehouse decisions, motion and safety concerns tangled in the same place.
The same line, with Secure Sorter
- Verified identity — scan, weight, size and label — before a lane is assigned.
- Checked divert logic with a confirm, plus recirculation, missort and lost-carton handling.
- A fail-safe exception lane when data is missing or late. No guessed destination.
- Drag-and-drop HMI, a 119-piece conveyor library, and looks chosen with operations.
- Historian, shift and sorter reports, and an audit trail on license plates and alarms.
- Multi-vendor drivers and administrator-controlled, audited live writes, commissioned per site. Motion and safety stay on the PLC and hardwired circuits.
Four rules the software does not break
- The PLC owns motion. Motor-driven roller cards own zero-pressure accumulation. Secure Sorter decides destinations and records events. The PLC executes and confirms.
- Safety stays hardwired. This is a non-safety system. It may display safety status. It does not command a safety function, and it does not claim a SIL or PL rating.
- Fail safe, never guess. No data, late data, a no-read or a timeout sends the carton to the exception lane or a recirculation path.
- Configuration over one-off code. Layouts, routes and rules are set up for the site by Electrol engineers, then run as a signed project image — on Windows, macOS or Linux, on the plant network, without a cloud connection to sort.
Not a safety device. Graphics of e-stops or similar controls on an operator screen are not a substitute for hardwired safety. Personnel protection is designed by Electrol as part of the physical system — safety PLC, relays and field devices — not by this website, and not by a software click.
Talk to Electrol about your line
Secure Sorter is used in Electrol Systems integration work. It is not a self-serve download. Write to [email protected] and tell us about the line.