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COS Tunnel expands the Clustag RFID portfolio with a flexible RFID tunnel designed to integrate directly over existing conveyor systems. It enables automated verification of boxes, parcels and bags while minimising infrastructure changes, reducing installation time and accelerating RFID adoption across logistics operations.

As distribution centres continue to look for faster and more agile ways to deploy RFID technology, COS Tunnel provides a practical solution for facilities where operational continuity, rapid deployment and seamless integration are essential.

COS Tunnel is designed for projects where flexibility, rapid integration and minimal impact on infrastructure are the deciding factors.” says Manolo Reguart, CEO of Clustag.

Why COS Tunnel is changing RFID deployment

Many logistics operations want to automate verification processes without redesigning conveyor lines or interrupting day-to-day activity.

COS Tunnel addresses this challenge through an open architecture that integrates directly over existing conveyors. This approach allows companies to implement RFID technology faster while avoiding major modifications to their facilities.

COS Tunnel reduces installation complexity

Traditional RFID projects often require structural adaptations that increase deployment time and project costs.

COS Tunnel simplifies installation because the solution adapts to the conveyor instead of forcing the operation to adapt to the RFID system. As a result, companies can accelerate project execution and start generating value more quickly.

COS Tunnel adapts to existing logistics environments

The solution is configurable in width, height and operating layout, allowing it to fit different conveyor configurations and operational requirements.

This flexibility makes COS Tunnel especially attractive for brownfield facilities where maintaining productivity during implementation is a key requirement.

How COS Tunnel improves RFID verification

Beyond deployment flexibility, COS Tunnel incorporates technology specifically designed to deliver reliable RFID performance in real logistics environments.

The system includes an innovative RFID wave emission and reading-zone control technology developed by Clustag’s R&D team. This approach concentrates RFID reads within the parcel transit area, improving process reliability and ensuring accurate verification performance.

COS Tunnel adapts to real operational conditions

Every logistics operation presents different challenges.

COS Tunnel is configured according to:

• Conveyor speed
• Parcel density
• Distance between packages
• Environmental conditions
• Process requirements

This allows the solution to deliver performance tailored to the specific needs of each installation rather than relying on a one-size-fits-all approach. [COS Tunnel_EN.docx | Word]

COS Tunnel and Zentup integration

Capturing RFID data is only part of the process. The true value comes from transforming that information into operational intelligence.

COS Tunnel connects with business systems through the ZENTUP data capture platform, enabling seamless integration with:

• WMS
• ERP
• WCS
• WES

This software integration layer ensures that RFID events become actionable data that improves visibility, traceability and decision-making across the supply chain.

Why Zentup enhances COS Tunnel performance

By connecting RFID data directly with operational systems, Zentup helps organisations automate workflows and manage information in real time.

The result is a more connected, more efficient and more intelligent logistics operation.

Where COS Tunnel delivers value

COS Tunnel is designed for logistics processes where rapid implementation and infrastructure adaptability are essential.

Inbound verification

COS Tunnel automatically verifies incoming goods, helping organisations increase inventory visibility and improve receiving processes.

Outbound verification

Before shipments leave the facility, COS Tunnel validates parcels and logistics units to support order accuracy and operational efficiency.

Ecommerce fulfilment

High-volume ecommerce operations benefit from automated verification processes that support faster and more scalable order preparation.

Brownfield logistics projects

COS Tunnel is particularly suited to existing facilities where avoiding conveyor shutdowns and major infrastructure modifications is a critical project requirement.

COS Tunnel expands Clustag’s RFID portfolio

COS Tunnel complements the existing Clustag RFID solutions portfolio by offering a solution focused on flexibility and rapid deployment.

COS Tunnel does not replace MOT Station. Each solution addresses a different operational priority.” says Manolo Reguart. “COS excels where flexibility and rapid deployment are decisive, while MOT Station remains the benchmark for maximum accuracy and controlled RFID environments

This approach allows organisations to select the RFID solution that best matches their operational objectives, infrastructure conditions and deployment strategy

Frequently asked questions

Picking errors are one of the most underestimated threats in e-commerce logistics. While many companies focus on attracting new customers and accelerating deliveries, they often overlook a costly reality happening inside the warehouse. Every wrong item, missing product, or incorrect order shipped directly erodes profitability.

In highly competitive e-commerce environments, customers expect perfect fulfillment. A single mistake can trigger returns, customer service incidents, replacement shipments, and reputational damage. When picking processes are performed manually, these errors become increasingly difficult to control as order volumes grow.

Every picking error generates hidden costs that extend far beyond the value of the wrong product shipped.

Why manual picking generates costly mistakes

Manual picking relies heavily on human attention. Operators must identify locations, verify products, confirm quantities, and prepare orders under constant time pressure.

As SKU catalogs expand and order volumes increase, the probability of mistakes grows significantly.

Human errors are inevitable

Even highly trained warehouse employees are vulnerable to:

• Selecting the wrong product reference
• Picking incorrect quantities
• Forgetting items within an order
• Confusing similar-looking products
• Picking from incorrect locations

These mistakes become more frequent during seasonal peaks, promotions, or high-demand periods.

Complexity increases operational risk

Modern e-commerce operations often manage:

• Thousands of SKU references
• Multiple product variants
• Continuous inventory movements
• Same-day shipping commitments

Without real-time validation systems, warehouse teams depend entirely on visual checks and manual verification processes.

The result is simple: increased operational risk and reduced order accuracy.

The true cost of a picking error

Many organizations only calculate the direct cost associated with correcting an order. However, the financial impact is much larger.

Direct operational costs

When an incorrect order is shipped, companies typically incur:

1. Reverse logistics costs
2. Product return handling
3. Replacement shipment expenses
4. Customer service intervention time
5. Additional warehouse labor

Each error generates multiple operational activities that consume resources.

Indirect costs that hurt profitability

The most dangerous consequences are often invisible.

These include:

• Customer dissatisfaction
• Negative reviews
• Lower repurchase rates
• Reduced brand trust
• Increased customer acquisition costs

In e-commerce, customer experience is a competitive advantage. A fulfillment mistake can quickly become a lost customer.

Comparing manual versus automated validation

Operational challenge	Manual picking	RFID-enabled validation
Product verification	Visual inspection	Automatic identification
Order accuracy	Dependent on operator attention	Real-time validation
Error detection	After shipment	Before shipment
Scalability	Limited by workforce	Easily scalable
Customer satisfaction	Variable	Consistently high

How picking errors impact customer experience

The customer only sees one thing: whether the order was correct.

They do not distinguish between warehouse issues, inventory discrepancies, or operational complexities.

Wrong orders create immediate frustration

Receiving the wrong item causes:

• Disappointment
• Additional effort to process returns
• Delays in product availability
• Reduced trust in the retailer

A single negative experience may be enough to encourage customers to explore alternative brands.

Fast delivery means nothing if accuracy is missing

Many e-commerce businesses invest heavily in delivery speed.

However, delivering the wrong product quickly does not improve customer satisfaction.

Accuracy must come before speed.

Customers remember receiving the correct product more than they remember receiving it a few hours earlier.

How RFID transforms e-commerce order fulfillment

Reducing picking errors requires more than additional training or supervision. Businesses need automated verification mechanisms capable of identifying mistakes before orders leave the warehouse.

This is where RFID technology becomes a strategic advantage.

Real-time product identification

RFID allows every tagged item to be identified instantly without manual scanning.

During packing and dispatch operations, products can be automatically verified against the customer order.

This enables warehouses to detect discrepancies before shipment.

Automated order validation

With an RFID-powered e-commerce solution, organizations can:

• Verify order completeness automatically
• Detect incorrect products instantly
• Reduce manual quality controls
• Increase fulfillment accuracy
• Accelerate shipping processes

The result is a more reliable operation with fewer costly incidents.

Data-driven continuous improvement

Accurate visibility is essential for operational excellence.

Through Zentup, companies can transform fulfillment data into actionable insights, identifying:

• Error patterns
• Operational bottlenecks
• Productivity trends
• Inventory discrepancies

Data intelligence helps logistics leaders move from reactive problem-solving to proactive optimization.

Learn more about how data visibility improves warehouse performance through Zentup and connected logistics solutions available at Clustag.

Building a scalable and error-free e-commerce operation

As order volumes grow, manual controls become increasingly difficult to maintain.

Organizations that continue relying on manual picking often face:

• Higher operational costs
• Increased return rates
• Lower customer satisfaction
• Reduced profitability margins

Operational excellence requires automation

To create a scalable fulfillment process, businesses need technologies capable of:

• Automatically validating products
• Providing real-time inventory visibility
• Eliminating repetitive manual checks
• Supporting business growth without proportional labor increases

RFID-enabled e-commerce solutions provide exactly this foundation.

The competitive advantage of error-free fulfillment

Companies that consistently deliver accurate orders benefit from:

• Better customer retention
• Lower logistics costs
• Higher operational efficiency
• Stronger brand reputation
• Improved profitability

In today’s e-commerce landscape, fulfillment accuracy is no longer a warehouse metric. It is a business growth driver.

Frequently asked questions

How much can picking errors impact profitability?

Picking errors generate direct costs such as returns, replacement shipments, and customer service interventions. They also create indirect costs through customer dissatisfaction and lost future sales.

Why do manual picking processes generate mistakes?

Manual operations depend on human attention and verification. As SKU volumes and order complexity increase, the probability of errors rises.

What is the biggest hidden cost of picking errors?

The largest hidden cost is often customer churn. A poor fulfillment experience can damage trust and reduce repeat purchases.

How does RFID reduce picking errors?

RFID automatically identifies products and validates orders in real time, allowing warehouses to detect mistakes before shipment.

Can RFID improve warehouse productivity?

Yes. RFID reduces manual verification tasks, speeds up fulfillment processes, and enhances operational efficiency.

What role does Zentup play in fulfillment optimization?

Zentup provides operational intelligence by transforming logistics data into insights that help companies improve accuracy and performance.

Is RFID only useful for large e-commerce operations?

No. Businesses of all sizes can benefit from improved order accuracy, reduced returns, and greater warehouse visibility.

How can companies test RFID solutions before implementation?

Organizations can visit the Clustag Customer Experience Center to evaluate RFID use cases using their own products and operational scenarios.

Ready to eliminate costly picking errors?

Picking mistakes may seem like isolated incidents, but they create a continuous drain on profitability, customer satisfaction, and operational efficiency.

If you want to discover how RFID-powered e-commerce solutions can help you achieve near-perfect order accuracy, contact our team or visit our Customer Experience Center to test the technology with your own products and processes.