RFID Tunnel for Carton Audits, Transfers and Receiving
Scan the carton’s LPN, push it through the Senitron RFID tunnel, and in 1–3 seconds the screen shows exactly what is inside — Perfect Match, Less, More or Wrong Items — without opening the box. Audit every outbound transfer and inbound shipment, audit at the pack station before cartons are sealed, and send every result to your WMS or ERP.
Audit Every Carton Without Opening It
As each carton passes through the tunnel, the fixed Zebra reader and antennas — tuned for dense cartons, with side-read blocking — capture every RFID tag inside, compare them with the LPN or the expected count, and light up the operator’s touchscreen:
- Perfect Match (green) — the carton holds exactly what it should.
- Exception Less (red) — items are missing, with the SKUs and quantities.
- Exception More (amber) — extra units are in the box.
- Exception Wrong Items (purple) — a tag that is not on the manifest.
- Exception cartons are set aside, fixed with a handheld scan and appended to the same tunnel session.
Three Ways to Run the Tunnel
Full LPN verification
Your WMS sends the ASN with each LPN and its expected items; the operator scans the carton barcode and the tunnel gives real-time feedback on all four results. The highest-accuracy mode.
Expected-count audit
No LPN data but you know the count? The operator enters the expected quantity before the carton passes through, and Senitron checks it for match, less or more.
Record-only mode
No audit: the tunnel simply records exactly what was in each carton, building a carton-level record the receiving site can use.
Same software, other read points
The same license runs on a plain fixed reader and antenna without the enclosure — for example an upright doorway portal for garments on hangers.
Outbound Transfers: Carton 2 of 50
For DC-to-store and DC-to-DC transfers, the Outbound Transfer Advanced module adds a shipment-level counter on top of the carton audit.
- The screen shows progress for the whole shipment (“Carton 2 of 50”) as each carton is verified.
- At the end of the shipment it flags any missing cartons (“4 cartons not received”) so they are found before the truck leaves.
- Start a transfer with an order or reference number to audit against the expected cartons, or without one to simply record cartons and contents.
- The receiving store or DC pulls up the transfer and receives it by RFID scan in seconds, with every difference flagged.
- Ideal for high-value inbound shipments where every carton matters, too.
Inbound Receiving With Handheld RFID Scanners
No tunnel at the receiving dock, or a container that needs unloading fast? Mobile RFID Receiving spreads the work across your team.
- Your WMS sends the ASN (for example “shipment #5555 has 5,000 units”) to Senitron.
- 5–10 operators each take a handheld RFID scanner and scan cartons in parallel; every carton gets a unique ID automatically if it does not already have one.
- Everyone sees the same live counter: “2,347 of 5,000 units read.”
- When scanning is done, Senitron flags every short SKU and every short carton, so only those cartons are re-opened and audited — not the whole shipment.
Catch Errors at the Pack Station
Stop mistakes before the carton is sealed. Pack-station audits work on their own or together with a tunnel, which then does the final shipment audit as cartons leave the DC.
- Handheld at the pack station: the packer scans the carton’s LPN, Senitron pulls up the expected items, and the screen updates live as each item goes in — “Expected 6 · Read 3 · Missing 3” — flagging any unexpected item.
- Fixed RFID “bucket”: a reader with a downward-facing antenna above or in the pack table reads every item hands-free as it is dropped in — ideal for high pack volumes and busy hands.
- Catches about 99% of pack errors upfront, eliminating downstream shipping errors.
One Live Dashboard for Every Station
Tunnels, pack stations and handhelds all report to the Senitron RFID platform in real time.
- Live counts by shipment, carton and station on a wall screen or any browser.
- Print and encode RFID labels, run RFID inventory counts and manage transfers from the same platform and its Android app.
- Full history of every carton audit for vendor claims, chargebacks and customer disputes.
- See also RFID order picking and wave picking.
The Senitron RFID Tunnel Unit
Get a complete tunnel from Senitron, or run the Senitron software on a tunnel you source yourself.
- Complete unit: yellow-frame enclosure, flexible roller conveyor, mounted Zebra fixed RFID reader and antennas optimized for dense cartons with side-read blocking, brackets and cabling.
- Remote installation support: our team walks your installers (for example your in-house IT) through assembly by video and confirms the tunnel is installed, tested and calibrated.
- Operator station kit: mini PC, 15.6″ touchscreen on a monitor arm, webcam, wireless barcode scanner, keyboard, PoE switch, cabling and a wall-mounted folding table.
- Volume pricing for multiple tunnels and sites.
Support Included Seven Days a Week
Unlimited phone, email and video support
Monday–Friday 6 AM–6 PM and Saturday–Sunday 6 AM–4 PM Pacific, included with all software.
After-hours emergency support
Direct cell numbers to senior support managers, and all senior support engineers are based in the USA.
Works With Your WMS and ERP
Expected cartons come from your WMS or ERP as ASN, transfer or purchase order data, and audit results go back. Senitron integrates out of the box with NetSuite, Acumatica and Microsoft Dynamics 365 / Business Central. See also RFID for logistics, 3PLs and distribution centers and the RFID warehouse management system.
RFID Tunnel: Common Questions
What is an RFID tunnel?
An RFID tunnel is an enclosure with a fixed RFID reader and antennas, usually on a conveyor. Cartons pass through it and every RFID tag inside is read in 1 to 3 seconds, so the contents can be verified without opening the box.
What does the RFID tunnel show the operator?
One of four results on the touchscreen: Perfect Match (green), Exception Less with the missing items (red), Exception More with the extra items (amber), or Exception Wrong Items for tags not on the manifest (purple).
Do I need LPN or ASN data to use the tunnel?
No. With LPN data you get full item-level verification; with only an expected quantity Senitron checks the count; and with no data at all the tunnel records what is in each carton for receiving at the other end.
Can the tunnel verify outbound transfers to stores?
Yes. The Outbound Transfer Advanced module counts cartons against the shipment (for example "Carton 2 of 50"), flags missing cartons before the truck leaves, and the store receives the transfer by RFID scan on arrival.
Can we receive large inbound shipments without a tunnel?
Yes. With Mobile RFID Receiving, 5 to 10 operators scan cartons in parallel with handheld RFID scanners against the ASN, all watching one live counter, and Senitron flags only the short SKUs and cartons for re-checking.
Can RFID catch packing errors before cartons are sealed?
Yes. At the pack station a handheld RFID scanner or a fixed RFID bucket shows Expected, Read and Missing live for each carton and flags unexpected items, catching about 99% of pack errors upfront.
Does Senitron integrate with our WMS or ERP?
Yes. Expected cartons come from your WMS or ERP and results are sent back. Senitron integrates out of the box with NetSuite, Acumatica and Microsoft Dynamics 365 / Business Central, and other systems connect through import and export or a custom integration.
Experience RFID Risk-Free: 30-Day Money-Back Guarantee
An RFID specialist will walk you through carton audits, outbound transfers, inbound receiving and pack-station audits for your DC.
- Live demo of Senitron RFID inventory software
- How many cartons an hour one tunnel can verify
- Tunnel, readers and labels sized for your volume
- A no-obligation quote
- No contract — month-to-month, cancel anytime
- 30-day money-back guarantee — zero risk
- 7-day USA support — direct line to the senior team
Prefer to talk now? Call (213) 455-4977
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