Pick-to-Light

What is pick-to-light?

Pick-to-light (PTL or light-directed picking) is a warehouse automation technology that uses lights and digital displays mounted on storage locations to guide operatives to the correct items and quantities.

When operatives scan an order barcode, illuminated indicators activate at pick locations, showing which products to retrieve and how many units to collect.

Benefits of pick-to-light automation

Pick-to-light solutions improve accuracy, reducing the risk of returns. Pick-to-light can be used alongside order batching, meaning operatives can fulfill multiple orders simultaneously.

Pick-to-light is also highly intuitive and requires minimal instruction, making it easy to train new and seasonal operatives.

Who benefits most from pick-to-light warehouse solutions?

High-volume distribution centers with repetitive picking benefit most from pick-to-light automation.

In particular, pick-to-light technology suits pharmaceutical distribution, cosmetics fulfillment and e-commerce operations with high order volumes.

How pick-to-light technology works

PTL systems consist of light modules installed on shelving or flow racks, each connected to the warehouse management system (WMS) through controllers that manage pick task assignments.

Operatives scan a tote or cart barcode to fulfill an order, which triggers lights to illuminate at storage locations containing required items. If order batching is in use, lights display different colors or segments for each order, showing operatives which items go into which totes or cart.

Digital displays show quantities needed and operatives confirm picks by pressing buttons on the light modules.