US Patent 8156013 Methods and apparatus for fulfilling tote deliveries

Methods and apparatus for fulfilling tote delivery orders. A tote delivery service directs delivery of items ordered by customers via a network site to delivery addresses corresponding to the customers in reusable totes on assigned tote delivery days. Tote delivery data may be processed to generate bulk transfer data for fulfillment centers and zone delivery data for sortation nodes. Each fulfillment center may pick items indicated by the bulk transfer data and bulk transfer the items to particular sortation nodes. At a sortation node, the items in the received bulk transfers, and possibly items received from other sources such as direct transfers from vendors, are rebinned into totes corresponding to delivery addresses in zones. The totes are loaded onto delivery vehicles, which deliver the totes to the delivery addresses in particular zones served by the sortation node. The zones and tote delivery days may be determined by zip code.