Pallet Shuttle Warehouse

Nowadays, modern warehouses need to meet three important factors: high storage density, low cost, and fast import/export speed. Understanding this trend, Intech Group has developed the Pallet Shuttle Automated Warehouse System, a flexible and efficient high-density storage solution. This pallet shuttle system offers reasonable investment costs but outstanding efficiency, especially suitable for compact warehouses, cold storage warehouses, consumer product warehouses or warehouses with a large number of pallets per SKU. With Pallet Shuttle, Intech Group helps businesses optimize space, reduce operating costs and increase the speed of goods processing, perfectly meeting market requirements.
 

What is the Pallet Shuttle System?

Pallet Shuttle is an automatic pallet shuttle system, used in smart warehouses to optimize the storage and management of goods. This is a compact device, running on rails in racks, capable of automatically loading and unloading pallets quickly and accurately. Pallet Shuttle is often combined with a stacker crane or operated independently, helping to move pallets to storage locations or retrieve them according to commands from warehouse management software (WMS).

Pallet Shuttle Intech is an advanced automatic storage system, researched, developed and completed by us, officially launched on the market in 2022. Robot Shuttle - a core component in the Pallet Shuttle warehouse system - takes on the role of transporting and unloading goods in the warehouse shelves in an optimal way. This is a line of robots that move on rails in storage lanes, performing efficient pallet loading and unloading, controlled by an intelligent robot forklift system and scientific programming.
 

What is a Pallet Shuttle Warehouse?

Pallet Shuttle Warehouse is an automated or semi-automated warehouse system that uses Pallet Shuttle technology - automatic shuttles running on rails in racks to store and retrieve pallets quickly and accurately. This system is designed to optimize storage space with high density, reduce operating costs and increase the speed of import/export of goods. Pallet Shuttle is usually controlled by warehouse management software (WMS), supporting import/export according to the FIFO (First In, First Out) or LIFO (Last In, First Out) principle.
 

Intech pallet shuttle warehouse operation video
 

How the Pallet Shuttle Warehouse Works

In the Pallet Shuttle Radio Semi-Automated Warehouse System, the forklift will place the pallet on the rail at the beginning of each storage lane. The Shuttle then automatically lifts and moves the pallet to the nearest empty position in the lane, optimizing storage space effectively. The movements of the Shuttle inside the rack system are automatically controlled, following the operator's command through a convenient control handle. This solution not only saves space but also increases the speed of import/export, bringing outstanding efficiency to modern warehouses.
 

 

- FIFO and LIFO Loading/Output Methods in the Radio Shuttle Pallet System

 

Intech Group's Radio Shuttle Pallet System flexibly supports two loading/unloading methods, meeting the diverse needs of businesses:

• FIFO (First In, First Out): The first pallet placed in each lane will be the first pallet removed from that lane. Forklifts operate on both sides of the warehouse – one side for loading and the other side for unloading. This method is ideal for warehouses designed as a buffer zone between two areas, such as intermediate warehouses or manufacturing warehouses.
• LIFO (Last In, First Out): The last pallet placed in each lane will be the first pallet removed. Loading and unloading take place on the same side of the warehouse, making this the most popular method in warehouses using the Radio Shuttle Pallet System, especially suitable for compact warehouses or cold storage.

 

Step 1: The forklift lifts the shuttle onto the shelf lane that needs to store or export pallets.	Step 2: Next, the forklift moves the pallet to the storage lane. The forklift never enters the rack.
Step 3: The operator uses the remote to send commands to the Shuttle. Once the pallet's position has been determined, the shuttle will lift the pallet and move along the depth of the rack to the nearest pallet, then lower the pallet.	Step 4: The shuttle returns to the front of the racking lane to store the next pallet (if needed) until the racking lane is full. To export pallets, the operator performs the same operation.

 

- Functions that the Shuttle Radio warehouse system can perform:

 

Standard				Advanced
Storage: Put each pallet on the shelf				Push pallets: automatically stack pallets to make space (FIFO function - stack goods for storage)
Output: Take each pallet to the end of the shelf				Pull pallets: automatically stack pallets to make space (FIFO function - stack goods for shipping)
Continuous unloading: Take the pallet to the end of the shelf, while waiting for the forklift to pick up the pallet, continue to run in to take out another pallet.				Wait for unloading: take the first pallet to the front of the shelf, then go back to continue taking the second pallet, if the first pallet is not taken at the front of the shelf, it will wait until the first pallet is taken, then automatically place the second pallet in the position of the first pallet.
Set the distance between pallets from 20-150mm				Prevent collision between shuttle vehicles on the same shelf lane.
Remote can control 4 devices at the same time				Count the number of pallets in stock

 

Robot pallet shuttle warehouse overview

As an important part of the Intech Pallet Shuttle system, Robot Shuttle ensures that pallet movement in the warehouse is fast and optimal.
 

- What is a Shuttle Robot?

Shuttle Robots are advanced automated devices designed to transport goods or materials in areas such as logistics, warehousing and manufacturing. These robots can move along fixed or flexible routes depending on the design and technology applied, bringing high efficiency in managing and storing goods.
 

- Shuttle Robot Structure

Shuttle Robots are designed with high speed, integrated with many safety features and the structure includes the following main parts:

 

• Pallet lifting cluster: Ensures accurate and safe lifting and lowering of pallets.
• Lithium battery cluster: Provides durable energy for the robot to operate continuously.
• Guide wheel cluster: Supports the robot to move accurately on the rail.
• Drive wheel cluster: Ensures stable and fast movement.
• Safety sensor: Detects obstacles, ensuring safe operation.
• Emergency stop button: Allows immediate stop in emergency situations.
• Distance sensor: Measures the distance for the robot to move accurately.
• Pallet check sensor: Checks the position and status of the pallet, avoiding errors.

The technology used for Robot Shuttle is often equipped with technologies such as laser guidance systems, sensors, and management software to navigate and optimize the movement process. These technologies allow them to operate efficiently and safely in different working environments.

 

- Control handle structure:

The control panel is designed with function keys for easy operation.
 

1. Display screen

2. Single input button

3. Continuous input button

4. Manual button cluster

5. Power on/off button

6. Single output button

7. Continuous output button

8. Stop button

9. Vehicle selection button cluster
 

Full structure of pallet shuttle warehouse

The main components of a shuttle pallet warehouse are as follows:

1. Shelf frame

The shelf frame, also known as the pallet rack, is an important part of the warehouse system, used to lift, support and store goods scientifically. In Intech Group's Pallet Shuttle warehouses, the shelf frame is designed with a variety of styles, sizes and loads, meeting the storage needs of many industries, from logistics, manufacturing to supermarkets.


Shelf frames are often used in combination with the following types of pallets to optimize storage:

• Plastic Pallets: Made from recycled or new plastic, plastic pallets have high load-bearing capacity, are durable, do not rot and are environmentally friendly. Suitable for many fields such as warehouses, supermarkets, and logistics, plastic pallets can be reused many times, are easy to clean, helping to save on transportation and maintenance costs and reduce environmental impact.
• Wooden Pallets: A popular choice due to their reasonable price, abundant supply according to orders, sturdy structure and ease of use. Wooden pallets are often used in warehouses to store a variety of goods, bringing flexibility and cost savings to businesses.
• Iron Pallets: Made from iron or steel, iron pallets have superior load-bearing capacity, suitable for heavy goods. However, this type of pallet is rarely used due to its high cost, heavy weight and easy oxidation if not properly stored.

2. Forklift: Efficient transportation equipment in the warehouse

Forklift is a specialized equipment for transporting, lifting and unloading goods, commonly used in warehouses, seaports, warehouses and production facilities. With an optimal design, forklift helps move and arrange goods quickly, effectively, saving time and effort.

In automated warehouse systems such as Intech Group's Pallet Shuttle, forklift plays an important role in placing pallets on rails or supporting import/export of goods, improving the efficiency of modern warehouse operations.

 

Forklift in smart warehouse
 

3. Robot Shuttle AGV - Automatic Pickup Vehicle

Robot Shuttle AGV (Automated Guided Vehicle) is an automatic pick-up vehicle, used in automation systems in warehouses and factories. This robot is designed to move automatically, pick up and transport goods between points on shelves according to pre-programmed routes, remotely controlled through an intelligent management system.

 

Automated Pickup Vehicles in Smart Warehouses
 

Advantages and disadvantages of Pallet Shuttle Warehouse

The Pallet Shuttle Warehouse system is a modern warehouse automation solution, bringing many benefits but also some limitations. Here is a detailed analysis:

Advantages:

• Increased storage density: Optimizes space 2-3 times compared to traditional shelves, suitable for compact warehouses or warehouses with large cargo volume, little mixing.
• Fast import/export speed: Shuttle Robot automatically moves pallets on rails, reducing loading/unloading time, improving operating efficiency.
• Cost savings: Reduce labor and operating costs thanks to automation, especially effective in cold storage or consumer product warehouses.
• Flexible management: Supports import/export according to FIFO (First In, First Out) or LIFO (Last In, First Out) principles, meeting the diverse needs of businesses.
• High Accuracy: Integrated WMS management software and smart sensors ensure accurate pallet transportation and reduce errors.
• Operational safety: Robot Shuttle is equipped with safety sensors, emergency stop buttons and protection systems, ensuring safety for operators and goods.
• Easily expandable: Flexible design, allowing expansion or adjustment of the system according to the development needs of the business.

Disadvantages:

• High initial investment cost: Installing the Pallet Shuttle system, including robots, tracks and WMS software, requires a large investment, which may not be suitable for small businesses.
• Reliant on maintenance: Robot Shuttle and automated equipment need regular maintenance to ensure stable operation, which may incur maintenance costs.
• Limited to diverse goods: The system works best with less mixed goods, not suitable for warehouses with many types of small or heterogeneous goods.
• Technology Dependency: In the event of a power outage or system failure, warehouse operations can be disrupted, requiring backup systems or rapid response by technicians.

 

Applications of Pallet Shuttle Warehouse

The Pallet Shuttle Warehouse system, such as the Intech Group's Intech Pallet Shuttle solution, is designed to meet the needs of storing and managing goods in many industries. With the ability to automate and optimize space, this system has the following outstanding applications:
 

• Cold storage and food preservation: Suitable for cold storage thanks to its ability to operate effectively in low temperature environments, reducing the exposure time of employees to cold conditions. Ensure the management of perishable goods according to the FIFO (First In, First Out) principle, minimizing waste.
• Intermediate and distribution warehouses: Ideal for intermediate warehouses, where goods have been classified according to orders, with large traffic but little mixing. Support fast import/export, ensuring goods are circulated effectively between production or transportation areas.
• Consumer product warehouse: Suitable for storing consumer products with a large number of pallets per SKU, such as beverages, packaged goods or household goods. Increase storage density, reduce occupied space, suitable for distribution centers or supermarkets.
• Compact warehouse and limited space: Optimized for warehouses with limited area thanks to high-density storage capacity, making the most of height and deep space in shelves. Shuttle Robot moves pallets into deep positions, reducing the need for aisles, saving space.
• Industrial and manufacturing warehouse: Applied in industries such as pharmaceuticals, electronic components, or chemicals, where heavy and homogeneous goods need to be stored. Supports LIFO (Last In, First Out) or FIFO method, flexibly meeting production and transportation needs.

 

Pallet Shuttle Warehouse installation cost and influencing factors

Installing a Pallet Shuttle Warehouse requires a significant investment, depending on many factors. Here are the main factors that affect costs and a breakdown:

• Warehouse size and area: Warehouse area, shelf height (typically 3,500 mm to 15,000 mm), and the amount of goods stored directly affect costs. Larger warehouses require more racks, rails, and robots, increasing equipment and installation costs.
• Shelving and rail systems: The cost includes the racking and rail systems for the Shuttle Robot. This is a major cost, especially when deep racking (up to 40 m) is required to optimize storage space.
• Number of Shuttle Robots: Each Shuttle Robot operates on one lane of shelves, and the cost of these robots accounts for the majority of the total investment. A large warehouse may require multiple robots to ensure performance, increasing costs significantly.
• Management software (WMS): The warehouse management system WMS, integrated with ERP for automated control, is also an important cost. This software helps optimize the import/export process and manage goods, but implementation costs can be high depending on the level of customization.
• Installation and training costs: The installation of a Pallet Shuttle system can take anywhere from several months to a year, depending on the size of the project. Installation costs include labor and supporting equipment. Training staff to operate and maintain the system also requires costs, especially when a professional team is needed to ensure the system operates efficiently.
• Maintenance and repair: Shuttle robots and automated equipment require regular maintenance to maintain performance, resulting in long-term maintenance costs.

 

- Estimated Cost:

The cost of installing a Pallet Shuttle Warehouse can vary greatly, from several hundred million to tens of billions of VND, depending on the scale and specific requirements:

• Small warehouse (under 500 m²): The cost can range from 500 million to 2 billion VND, including basic shelves, 1-2 Shuttle Robots and simple WMS software.
• Medium warehouse (500-2,000 m²): The cost ranges from 2 billion to 10 billion VND, with a deep shelf system, 3-5 Shuttle Robots and ERP-integrated WMS.
• Large warehouse (over 2,000 m²): The cost can be up to 10-50 billion VND or more, with many robots, high shelves, and a comprehensive automation system.

 

Why choose Intech Group for pallet shuttle warehouse solutions?

Intech Group is a leading partner in Vietnam in the field of warehouse automation, and here are the reasons why you should choose Intech Group to deploy the Pallet Shuttle Warehouse solution:

• Experience and reputation: With many years of experience in the automation industry, Intech Group has affirmed its position through a series of successful projects, especially with the Intech Pallet Shuttle system launched in 2022, trusted by many businesses.
• Advanced technology solutions: Intech Group's Pallet Shuttle Warehouse integrates modern Shuttle Robots, smart WMS management software and the ability to connect to ERP, ensuring efficient, accurate operation and optimizing storage space 2-3 times more than traditional shelves.
• Flexible customization: Intech Group provides solutions tailored to the needs of each business, from cold storage, intermediate warehouse to production warehouse, supporting both FIFO and LIFO methods to meet diverse goods management requirements.
• Comprehensive support: From consulting, design, installation to maintenance, Intech Group is committed to accompanying customers, ensuring a stable and long-term efficient operating system.
• Long-term cost savings: Although the initial investment cost may be high, the Pallet Shuttle Warehouse solution from Intech Group helps reduce operating costs, save labor and increase productivity, bringing sustainable economic value.
• Multi-industry application: The system is suitable for many fields such as logistics, food, pharmaceuticals and manufacturing, especially effective in compact warehouses or warehouses with large cargo volumes and little mixing.

Choosing Intech Group to deploy the Pallet Shuttle Warehouse solution is a smart decision, helping businesses modernize their warehouses, improve efficiency and competitiveness. Contact Intech Group today to receive the best advice and solutions for your warehouse!
 

• Hotline: 0966 966 032
• Email: info@intech-group.vn
• Address: Lot 6, Lai Xa Industrial Park, Tay Tuu Ward, Hanoi City