Shuttle Racking System
Shuttle racking (or pallet shuttle) is a semi-automated storage system utilizing motorized shuttles that move independently within racking channels to place and retrieve pallets. Controlled by operators via remote or tablet, the system massively increases storage density, throughput, and safety—making it ideal for warehouses managing high volumes with LIFO or FIFO workflows.
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Features & Specifications
Ideal Applications & Use Cases
Cold storage and frozen warehouses: Optimize expensive chilled space; shuttles reduce energy consumption by minimizing open aisle time.
High-throughput logistics hubs: Fast pallet in/out cycles for consumer goods, 3PL, and e-commerce distribution centers.
Bulk and buffer storage: Long-term holding or staging for large SKU batches with infrequent individual pallet access.
Manufacturing plants: Store raw materials or finished pallets for “just-in-time” line feeding or outbound handling.
Ideal Applications & Use Cases
Cold storage and frozen warehouses: Optimize expensive chilled space; shuttles reduce energy consumption by minimizing open aisle time.
High-throughput logistics hubs: Fast pallet in/out cycles for consumer goods, 3PL, and e-commerce distribution centers.
Bulk and buffer storage: Long-term holding or staging for large SKU batches with infrequent individual pallet access.
Manufacturing plants: Store raw materials or finished pallets for “just-in-time” line feeding or outbound handling.
Key Benefits
Maximizes storage density: Virtually eliminates the need for multiple aisles and can fill warehouse depths previously unreachable with forklifts alone.
Rapid throughput: Pallets moved swiftly by shuttles; forklifts only operate at channel entrances, reducing travel time and bottlenecks.
Flexible inventory control: Easily switch between LIFO and FIFO operation; channels can be assigned by SKU, batch, or production date.
Labor and cost savings: Reduces forklift travel, labor input, and risk of rack damage—saving energy, time, and operational costs.
Superior safety: Minimizes forklift entry into racks, lowering the risk of accidents and pallet/rack damage.
Ideal for automation: Systems can be modularly upgraded to full automation with stacker cranes, conveyors, or WMS integration.
Key Benefits
Maximizes storage density: Virtually eliminates the need for multiple aisles and can fill warehouse depths previously unreachable with forklifts alone.
Rapid throughput: Pallets moved swiftly by shuttles; forklifts only operate at channel entrances, reducing travel time and bottlenecks.
Flexible inventory control: Easily switch between LIFO and FIFO operation; channels can be assigned by SKU, batch, or production date.
Labor and cost savings: Reduces forklift travel, labor input, and risk of rack damage—saving energy, time, and operational costs.
Superior safety: Minimizes forklift entry into racks, lowering the risk of accidents and pallet/rack damage.
Ideal for automation: Systems can be modularly upgraded to full automation with stacker cranes, conveyors, or WMS integration.
Shuttle Racking Case Highlights
Frozen Food Warehouse, Hyderabad
Semi-Automated Shuttle Racking
Cut loading/unloading times by 60% in a sub-zero facility and increased storage density by 90%.
Consumer Goods DC, Chennai
Pallet Shuttle Rack System
Doubled throughput with 50+ channel, multi-SKU operation and remote inventory management.
Bulk Storage, Gujarat
Deep-Channel Shuttle Racking
Enabled batch management and rapid pallet turnaround for high-volume industrial supplies.
Shuttle Racking vs. Drive-In & Pallet Flow Comparison
| Feature | Shuttle Racking | Drive-In Racking | Gravity Flow Racking |
|---|---|---|---|
| Storage Density | Very high (deep channels) | Very high | High |
| Pallet Movement | Automated (shuttle-driven) | Manual (forklift) | Automatic (gravity-fed) |
| Throughput | Very high | Medium | High |
| Inventory Control | FIFO or LIFO (configurable) | LIFO/FIFO (less flexible) | FIFO |
| Aisle Requirement | Minimal | Minimal | Minimal |
| Best Use | High volume, mixed SKUs, cold storage | Bulk storage (few SKUs) | Perishables, FIFO batches |