EuroSort goes the distance with sorters at Mouser Electronics

At its global distribution hub in Mansfield, Texas, electronic components distribution giant Mouser Electronics faced a growth ceiling. With more than 1.2 million active SKUs from 1,200 manufacturers, traditional sortation systems had reached their limits. Throughput bottlenecks. Tiny, bagged components literally floating off equipment. No room left to scale.

The solution? A massive, custom-engineered sortation ecosystem from EuroSort – all powered by EtherCAT-enabled automation and safety from Beckhoff.

This large-scale installation includes:

- Four unique sorter technologies

- Over half a mile of track

- Thousands of destinations packed into a mezzanine with just 14 feet of clearance

- Processing up to 30,000 items per hour per sorter

- More than 40,000 EtherCAT I/O points on the largest machine

At the core of it all is a high-performance control system from Beckhoff synchronized over EtherCAT. With scan times under 300 microseconds and fully integrated motion, safety, networking, and diagnostics, EuroSort delivered the speed, precision, and scalability Mouser needed.

The results:

- Nearly doubled put rates on goods-to-person systems

- Operators reaching up to 600 items per hour

- A scalable foundation for future high-density consolidation

Watch the full video case study to see how EuroSort and Beckhoff helped Mouser Electronics set new benchmarks in global electronic components fulfillment.