Smart Pallet Shuttle Solution Elevates 3PL Capacity to 46,000 Pallet Locations

The 3PL industry faces a number of key challenges in today’s fast-paced logistics environment. Pressure on warehouse capacity, the need to store an increased volume of goods and more varied SKUs, along with increasingly tight delivery times, all culminate in needing optimisation of efficiency, storage capacity, accuracy, and cost savings.

For this project, there were several specific and critical challenges in overhauling their warehousing operations, such as:

• Connect two existing storage chambers so that any pallet could be transported to either chamber. 
• Pallets at the top level should be strategically positioned following the angle of the roof to ensure the maximum storage capacity of the building.
• Ensuring the use of PPT (Powered Pallet Trucks) for both inbound and outbound pallet operations. 
• New inspection area to provide a dedicated zone to showcase the system to clients and potential customers, even calling down clients’ specific pallets for inspection. 
• This was all to be achieved within a large ‘black box’ storage space, with a requirement to operate behind closed doors and without the use of lights.

Providing a solution that met all the complex storage challenges for this 3PL meant the design and installation of an advanced storage system tailored to their specific needs. From goods-in through to despatch, this advanced automation solution combines pallet shuttle technology with high-density racking, lifts, a conveyor system, and powerful software, delivering exceptional storage capacity and throughput that is future-proofed for their needs. 

Automation Solution Components

 Pallet shuttles – 20 automated pallet shuttle taxis were installed across the two chambers of the warehouse, enabling operations to navigate the complex warehouse layout with precision. The design connected two separate chambers seamlessly, enabling efficient operations within their temperature requirements of between 2°C to 20°C.

Pallet conveyors – six reversible pallet conveyors were deployed extensively across the warehouse, designed to integrate seamlessly with pallet pump trucks used for both inbound and outbound pallet movements.

Racking system – 18.5 metres in height with eight levels, each with its own differing height as the racking structure was designed around the roof levels to ensure both storage density and the number of pallet storage locations would be optimised. At the point of entry at the inbound zone, the customer would determine the height of a pallet using in-built advanced scanners set within a frame, where the system decided where best to locate it within the racking structure based on its storage and movement requirements. Racking was also integrated to accommodate the cooling platforms which saved the customer significant costs on expensive additions to their warehouse.

Vertical lifts – six vertical lift systems were installed, each with a dual entry on each level of the racking to optimise the vertical space available and enhance overall storage capacity.

Software – a robust software suite was integrated with the existing WMS system to include pallet storage management, pallet traffic control, and route scheduling, which was fully operational from day one.

The customer was initially considering a VNA layout in their warehouse that would have provided a total pallet capacity of 26,000 pallets. However, the design and installation of this advanced storage solution with a combination of key automation technologies, provided a total capacity of over 46,000 pallet locations.

With the implementation of the pallet shuttle taxi system, no forklifts were required for the customer’s inbound and outbound processes. Whilst reducing labour costs, this also increases safety levels by eliminating the hazards associated with forklift operation.

Special features

• full control over switching palletised goods between the chilled and ambient temperature chambers
• a viewing area on the ground floor for their clients and potential customers to observe the system’s streamlined processes firsthand
• Warehouse operations are extremely efficient, enabling the entire process to be powered by a cooler system that runs entirely on energy generated by the solar panel system on the warehouse roof, meaning a net zero energy facility.
• 24/7 online technical support to ensure continuous operations and a quick resolution to any potential issues, alongside in-depth training for both maintenance and operations teams.

The implementation of this comprehensive automated solution delivered significant improvements to their storage operations - the benefits of which could be felt from day one.

• Solution doubled the storage capacity of the warehouse facility, now able to accommodate over 46,000 pallets. 
• Throughput of over 250 pallets per hour across both chambers, operating 24/7.
• Option to further scale the business in the future by implementing additional pallet shuttle taxis and automation components.
• Significant reduction of manual handling needs and labour costs, with only two operators required at any one time. 
• System design with built-in redundancy, enabling the pallet shuttle taxis to take an alternative route if a fault is detected on a specific line, reducing any potential downtime.
• Enhanced safety features including safety wire within the racking structure above ground level, with vertical wires installed on the access ladders.
• Manual working at height was eliminated using the pallet shuttles, removing any risk of potential injury associated with working on elevated levels.
• Forklift trucks were no longer required, boosting safety and reducing costs.
• Sustainable solution powered entirely by solar panels on the warehouse roof.