An Post installs second sorter

THE SYSTEM has already been operating under real-world conditions and was successfully tested during the most recent Christmas peak season, demonstrating strong performance, stability and throughput. This installation marks an important step in strengthening An Post’s regional parcel network as parcel volumes continue to grow across Ireland.

The E-Cross / Slim Line sorter processes up to 7,500 parcels per hour, supported by conveyor technology, a 5-Sided DWS, 8 accumulation chutes and 45 Direct Drop chutes. 

In recent years, growing parcel volumes have increased pressure on regional facilities, accelerating An Post’s transition from partially manual operations to scalable, automated solutions. Athlone was identified as a strategic location to support this shift and to add both capacity and operational resilience to the network.

Building on a proven concept

Following the successful deployment of a similar system at An Post’s Portlaoise facility, An Post again selected EAE Solutions as its partner for the Athlone project. The decision was based on confidence in the proven system concept, its suitability for the available footprint, and the existing working relationship between both teams.

“We chose to work again with EAE Solutions because the E-Cross / Slim Line crossbelt sorter had already proven itself and the project team understood our operational requirements from the outset,” says Alan Hayes, Automation Engineer at An Post.

The project was delivered on a tight schedule, with eight months between order and go-live. Thanks to close coordination, structured planning and strong on-site support, the sorter was fully operational in time for An Post’s busiest period of the year.

During the 2025 Christmas peak season, the system processed significantly higher parcel volumes with a stable flow and consistent accuracy. This first peak period confirmed that the sorter could reliably support high-intensity operations without disruption

“Within the first month we were already handling over 7,500 items per hour, which made a big difference during our peak season. Having the system live for the Christmas peak gave us immediate confidence in its stability and throughput under pressure,” says Alan Hayes.

The new system has added approximately 60,000 parcels per day to Athlone’s processing capacity, helping to relieve pressure on other facilities across the national network. At the same time, sorting accuracy has improved considerably, with a substantially lower mis-sort rate across a wide range of parcel types—from small items to large boxes and bags. 

“The sorter has turned out to be a solid value-for-money choice. It has reduced the amount of manual work we need, improved accuracy, and made a real difference to both the team on the floor and management,” Alan Hayes adds.

Based on early operational data, An Post expects to achieve a return on investment within 3.8 years.