Pallett Shuttle Solution Maximises Storage Capacity for Packaging Provider

There were a number of critical challenges to overcome to transform their warehouse operations and enhance efficiency and throughput. Key areas covered their stringent CO2 fire safety requirements and the need to comply with hazardous goods regulations. This meant tailored modifications were required such as specialised conveyors at fire safety doors, customised inner walls, and bespoke anchors used to enhance racking stability.

Additionally, the company required an automated storage solution that could maximise pallet storage within a compact space using the full height of the building and manage a diverse mix of product SKUs with varying batch sizes. 

To address the complex challenges, a robust and highly adaptable automated storage solution was designed and installed, completely tailored to their unique requirements using industry-leading technologies such as pallet shuttles, vertical lifts, conveyors, and a warehouse control system.

Automation Components

Pallett Shuttles - 4x bi-directional pallet shuttle taxis, capable of navigating the compact warehouse racking structure with speed and precision. These ensure pallets can be efficiently transported to any storage location within the racking.

Conveyors – the conveyor system handles inbound and outbound pallets and was integrated seamlessly with specialised fire safety doors and existing warehouse infrastructure for added safety.

Vertical Lifts – 2 x vertical lift systems were installed, designed to optimise the available vertical space up to 12.2m, contributing significantly to enhancing the overall storage capacity with each pallet shuttle able to reach every storage level.

Warehouse Control System – a robust software suite was designed for pallet storage management, traffic control, and route scheduling, and was fully integrated with the customer’s existing WMS. The software not only controlled the movement of pallets, but it also ensured the system could handle incoming volumes as high as 66 pallets per hour during peak times. 

Safety Measures – a number of safety measures were also integrated, such as fencing and light curtains, providing an effective, scalable, and future-proof solution designed to enhance safety across the warehouse.

The implementation of the pallet shuttle system has enhanced their overall warehouse operations. Storage density has been significantly increased and provides the capability to handle various SKU sizes and quantities more efficiently. By seamlessly integrating the new WCS with their existing WMS, inbound and outbound pallet operations now provide a smooth and reliable process for handling a wide range of palletised goods. Inbound pallet handling ranges from 33 pallets per hour, to 66 pallets per hour during peak operations. Outbound pallet handling is a constant 16 pallets per hour to efficiently meet customer requirements.

Additionally, the automated system was designed with adaptability in mind for future enhancements. These would include the likely implementation of Automated Guided Vehicles to further enhance operational efficiency and support their growth objectives.

The solution also met the company’s sustainability goals. With no need for the use of permanent lighting throughout the warehouse, the customer benefitted from substantial energy savings, further supported by the lightweight pallet shuttle taxis capable of handling goods up to 1000kg, thereby eliminating the need for a forklift or crane.

Overall the solution has provided a robust, efficient, and scalable solution to manage their growing warehouse operations, with in-built safety features and long term cost and sustainable benefits.