Pick to Light and Put to Light Systems

Pick to Light uses illuminated display units attached to storage locations that light up with a pick quantity to guide a warehouse operator directly to the right location and tell them how many items to pick — eliminating the need to search for items or read a printed pick list. Put to Light uses the same light-directed technology in reverse — guiding workers to place items into the correct destination bin or order box during sorting and order fulfilment. BCI's warehouse solution integrates both into a WMS-driven workflow for guided, auditable picking and putaway.

By eliminating list-based navigation, Pick to Light reduces mispicks caused by misread pick lists, incorrect location selection, and distraction errors. Operators simply follow the illuminated location and confirm the pick by pressing a button, reducing cognitive effort and enabling faster picking. This improves both pick speed and accuracy, particularly in high-SKU, multi-order environments.

Yes. Pick to Light systems can integrate with a WMS, ERP, or other in-house and third-party applications. The host system determines what needs to be picked and in what sequence, while the Pick to Light hardware guides operators using light signals. Picking data is automatically sent back to the connected system, ensuring inventory, order status, and transaction records are updated in real time without manual data entry.

Yes. BCI's warehouse solution is designed with modular scalability and rapid deployment options. Pick-to-light zones can be added or reconfigured as the warehouse layout or SKU range changes, without replacing the underlying WMS infrastructure. This makes it practical for operations that want to modernise picking in phases.

A worker typically scans an order, picklist, tote or item barcode to begin the task. The system activates a light at the relevant location and displays the required quantity. After completing the action, the worker confirms it using a button or scanner, and the transaction is communicated to the connected WMS or ERP system.

Light-directed systems can support e-commerce, retail, FMCG, pharmaceuticals, automotive, electronics, spare parts distribution, manufacturing, logistics and third-party warehousing. They are particularly relevant for operations with frequent piece picking, sorting, kitting or order consolidation.

Yes. Lights can guide an operator to the components required for a kit and display the quantity of each component to be picked. The connected software can also record completion and identify shortages or exceptions. BCI identifies kitting as a core application for its system.

Yes. Multiple orders can be grouped into a batch so that a worker picks the total required quantity of an SKU during one route. The items can subsequently be separated into individual orders using Put-to-Light or another sorting process.

Yes. Depending on the system configuration, colour-coded lights, displays or order containers can help employees process several orders in parallel.