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In fast-paced warehousing and logistics environments, accurate and timely order picking is critical to customer satisfaction and operational success. Manual picking methods are prone to errors, delays, and inefficiencies, especially as SKU complexity increases. To address these challenges, more warehouses are adopting Pick-to-Light (PTL) systems—an intuitive, visual solution designed to speed up picking, reduce training time, and improve order accuracy.
This article explains how Pick-to-Light works, its benefits, and why integrating it with smart shelf labeling technology can transform your warehouse operations.
What is a Pick-to-Light System?
A Pick-to-Light (PTL) system is a light-directed order fulfillment technology that uses indicator LEDs mounted on shelves or bins to guide warehouse workers to the correct pick locations. When a worker scans an order barcode or confirms a task via a handheld terminal, the corresponding shelf light turns on—often accompanied by a quantity display—highlighting where and how much to pick.
Pick-to-Light is ideal for:
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High-speed picking lines
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Zone picking operations
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Kitting and assembly processes
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E-commerce order fulfillment
How It Works (Step-by-Step)
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Order is Scanned or Received in WMS
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Light Modules Activate on the shelves where items are located
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Worker Picks Items according to the lighted indicators and displayed quantities
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Confirmation via Button or Scanner turns the light off
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Next Location Lights Up, guiding the worker step-by-step
This process reduces guesswork, minimizes walking time, and ensures real-time tracking.
Key Benefits of Pick-to-Light Systems
✅ 1. Faster Picking Speeds
Visual guidance eliminates the need for reading labels or searching by SKU, significantly reducing pick times.
✅ 2. Higher Order Accuracy
Error rates in manual picking can exceed 3%. PTL systems reduce this to below 0.2% by clearly identifying the correct items and quantities.
✅ 3. Minimal Training Required
New workers can become productive within hours. There’s no need to memorize complex warehouse layouts or product codes.
✅ 4. Scalable & Modular
PTL systems can grow with your business. You can start with a few zones and expand to thousands of pick faces across multiple facilities.
✅ 5. Real-Time Integration
Modern PTL systems integrate seamlessly with WMS, ERP, or MES platforms, offering complete traceability and inventory synchronization.
Pick-to-Light + ESL = Smart Shelf Technology
At Picksmart, we take Pick-to-Light to the next level by combining it with Electronic Shelf Labels (ESLs). This integration enables:
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Dual-function labels: Product info + light indicator in one compact device
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Wireless communication via 2.4GHz/868MHZ
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Battery-powered or wired modules, adaptable to any racking system
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LED lights with color options for multi-order picking or error alerts
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Mobile app or system backend for remote configuration and diagnostics
This hybrid solution reduces installation complexity and brings digital flexibility to shelf-level operations.
Use Case Scenarios
Retail & E-Commerce Fulfillment Centers
Quickly locate small SKUs, cosmetics, electronics, or apparel items for B2C shipping.
Manufacturing & Assembly Lines
Support parts kitting and Just-In-Time (JIT) workflows with accurate part identification.
Third-Party Logistics (3PL)
Handle diverse client inventories across shared warehouse zones with speed and precision.
Why Choose Picksmart’s Pick-to-Light Solutions?
Picksmart offers a modular, high-precision Pick-to-Light system featuring:
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Ultra-bright, customizable LED modules
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Wireless or hybrid power options
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Seamless WMS/API integration
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Real-time analytics and event logging
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Optional voice-pick or touchless confirmation features
Combined with our expertise in ESL and smart IoT solutions, we help clients reduce labor costs, improve order fulfillment speed, and gain a competitive edge in the digital warehouse era.