Pick to Light

Choosing Pick to Light components

Pick-to-light system selection comes down to the number of pick points, the integration with warehouse management software (WMS/WCS), the confirmation method preferred (button vs. beam-break vs. motion), and the visibility / brightness needed for the working environment.

Specs to confirm before ordering:

Module count per row, per zone, and total in the system — affects controller sizing
Indicator type: single color, multi-color (typical 4-color RGB or fixed 3-color red/amber/green), numeric display (for quantity), or alphanumeric
Confirmation method: tactile button (operator presses to confirm), photoelectric beam-break (operator's hand interrupts a beam), motion-detect (sensor in the indicator), or RFID-tagged pick container
Brightness — bright environments (well-lit warehouses) need brighter indicators
Mounting: bin-front clip-on, rail-mount, magnetic, or panel-mount
Communication to controller: RS-485, Ethernet, IO-Link, proprietary serial bus
WMS / WCS integration: API support, OPC UA, or vendor-specific middleware
Power: typically 24 VDC through trunk wiring to multiple modules
IP rating — typically IP54 for warehouse use, higher for refrigerated or wet environments

Common gotchas: pick-to-light systems are software-driven; the hardware alone is half the system. Without the matching controller software and integration with the WMS, the indicators do not light up in any useful sequence. Mixing pick-to-light brands within one system rarely works — controllers expect specific module protocols and addressing. Beam-break confirmation works fine for arm-reach picks but fails for tight bin spaces where the beam path is obstructed. Multi-color indicators are useful for distinguishing pick-this vs. confirm-pick vs. error states; single-color systems require operator training on flashing patterns.

Typical applications: order picking in distribution centers, parts kitting at assembly stations, lean manufacturing line-side replenishment, and quality-control marking on inspection stations. On legacy installations, in-kind hardware replacement preserves the controller software compatibility and the trunk wiring.

For obsolete pick-to-light hardware, send the OEM part number for a sourcing quote.

Do you stock obsolete pick-to-light hardware?

Yes. Discontinued Banner K50L first generations, retired Lightning Pick early codes, end-of-life Aioi modules, and earlier Murata pick-to-light are sourced through our supplier network.

Does pick-to-light come with software?

Hardware-only sales typically do not include the WMS-integration software. The OEM controller and software are usually separate purchases. For a complete-system quote, indicate whether you need just hardware or hardware + controller + software stack.

Can I add modules to an existing system?

Generally yes — pick-to-light systems are designed to expand. New modules need to be added to the controller's configuration and assigned addresses. We can supply matching modules for major OEMs.

What's the typical lifespan of a pick-to-light module?

LED indicators last 50,000+ hours. Confirmation buttons wear with cycle count; high-cycle picks may need button replacement after 1–2 years. Beam-break confirmation has no moving parts and effectively unlimited life.

Will a pick-to-light system work without WMS integration?

Standalone mode (manual sequencing via the controller's local interface) is possible but does not provide the productivity benefits of WMS-integrated picking. Most pick-to-light deployments are tied to WMS or WCS systems.

What is the warranty?

12-month functional warranty on hardware modules. Wear from extended high-cycle button use is not a warranty event.

Banner K30APT2GREQ Multipurpose Illuminated Touch Buttons

Banner K30APT2GXDQ Multipurpose Illuminated Touch Buttons

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Banner K50ABT2XGHQ Multipurpose Illuminated Touch Buttons

Banner K50ABTXGHQ Illuminated Touch Button

Banner K50CAPT2GREQ Illuminated Touch Button

Banner K50FLGRY6PQ Flat Mount Domed Indicators

Banner K50FLGRYNQ Flat Mount Domed Indicators

Banner K50L2RGB7Q Programmable Multicolor Indicator

Banner K50LGRBPQ General Purpose LED Indicator

Banner K50LGRXPQ Indicators

Banner K50LGRY2PQ General Purpose Indicators

Banner K50LGRY2PQ-804036 General Purpose Indicators

Banner K50LGRYB4PQ General Purpose Indicators

Banner K50LGRYBWNQ8 General Purpose Indicators

Banner K50LGRYBWPQ8 General Purpose Indicators

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