Pallet Shuttle System Provides 60% Increase in Storage Capacity for Frozen Food Specialist

The project presented a range of complex challenges for enhancing their current storage capabilities, from spatial constraints of the warehouse to environmental factors. 

The warehouse needed to be fully space-optimised through innovative use of both the horizontal and vertical space to maximise pallet storage within the existing footprint, as well as enable new technologies and automation equipment to be integrated with existing systems.

Operating cold storage services at temperatures of -22°C presented significant engineering challenges. The proposed solution would need to provide precise environmental control to ensure product integrity would be maintained at all times and strike the right balance between strict temperature control and the need for increased storage capacity and operational efficiency.

Addressing all the complexities of this project, an advanced automated storage system was devised and installed, combining pallet shuttles, vertical lifts, conveyors, and ERP integration, that would provide a significant increase in storage capacity without impacting strict temperature control.

Automation Components

Pallet shuttles – 10 automated guided pallet shuttle taxis were used to enhance manoeuvrability and the storage retrieval processes, as well as fully optimising the use of available space.

Vertical lifts – two vertical transfer units were integrated. These allow each pallet shuttle to reach any level of the racking structure (reaching up to 12m), increasing storage capacity and efficiently managing the vertical space available.

Pallet conveyors – two pallet conveyors were installed for infeed and outfeed to ensure the efficient movement of goods into and out of the storage area.

Software integration – the pallet shuttle system was fully integrated with the company’s existing ERP system to ensure seamless operations.

Project Results

The design and installation of this fully automated pallet shuttle system has delivered a number of key operational benefits for the company: 

Increased storage – the pallet shuttle system provided a critical 60% increase in storage capacity (now with 9,980 pallet locations), achieving a throughput of 60 pallets per hour for both inbound and outbound operations.

Increased efficiency – deploying the pallet shuttle system has significantly improved their just-in-time delivery capabilities, reducing manual handling and labour costs, while minimising the risk of damage to the pallet racking structure.

Temperature control – the integration of the pallet shuttle system was integrated adhering to the strict temperature control requirements of their cold storage facility.

This automation project showcases how advanced pallet shuttle technology is supporting cold storage business operations, to deliver enhanced services for food manufacturing and food retailer customers. It has delivered enhanced storage capacity, increased throughput for palletised goods in and out of the facility, reduced the cost of labour, and overall set new standards for cold storage solutions in the food distribution industry.