Order Picking for Food, FMCG, Pharmaceuticals companies

Order Picking for Food, FMCG, Pharmaceuticals companies

Falcon’s Pick to Light System for Order picking is an extremely powerful solution of picking directly to orders using Light directed Picking. Companies that have implemented this solution have seen several X increase in Pick rates per person along side a substantial increase in the picking accuracy. The solution is very relevant where the number of SKUs is not very high but the number of orders is very high.


The System comprises of Picking Racks with PTL Light indicators mounted on them.
Each Light represents One SKU stored in the Rack's Pick Location.
Each operator picks from a set of Picking Locations which is termed as the Picker's PICK ZONE.
Multiple Pick Zones can be created in the system depending upon the application.
An order flows into the Pick Zone 1 and the Picker scans the Order ID.
The Scan of Order ID, triggers the Lights of Glow for those SKUs that are required in the order.
The Lights also display the quantity of that SKU required in the order.
The operator Picks the required quantity of the SKU and presses the Confirm button to confirm the Pick.
The Light goes off and the picker picks the next SKU.
Once all the SKUs have been picked form the Pick Zone, the order is passed to the next Pick Zone to pick the SKUs stored on Pick Zone 2
The Pick Zone 1 receives the next order and repeats the Picking process.

This Solution is capable of increasing the Pick Rates several folds while maintaining high Accuracy rates.


Batch picking reduces multiple trips to same SKU bins and hence increases the overall productivity.
Integration of frames with conveyor system for post processing like shrink wrap, taping, Print & Apply and route wise sorting makes it a complete warehouse order processing solution.
Sorting process is completely paperless , thereby saving resources.
99.9% + accuracy is achieved in sorting.
Maintenance free system with easy troubleshooting.