May. 06, 2024
Choosing the right pallet shuttle system is crucial for optimizing your warehouse operations. As the demand for faster product turnarounds and increased storage efficiency rises, selecting the appropriate system becomes imperative. According to Maxrac, an ideal pallet shuttle system should meet your specific operational needs while enhancing productivity and minimizing labor costs.
Warehouse technology is constantly evolving to optimize supply chain efficiency. At the center of this push is automated storage and retrieval systems, and pallet shuttle systems are one of the core technologies in that genre of automation. Warehouse pallet shuttle systems are ideal for boosting operational efficiency without increasing your facility’s footprint and likely increasing the storage density as pallet shuttles have similarly narrow aisleway width to VNA storage but with even more space-efficient cross-aisles. Additionally, pallet shuttles offer the ability to increase automation incrementally and expedite material handling processes — saving you time and money.
The question is: which type of pallet shuttle is right for your operation? Let's explore the three core options, including their benefits, how they work, and when you should consider each type.
Pallet shuttle systems play a pivotal role in today's warehousing industry. They reduce labor dependency issues, lower direct labor costs, increase storage capacity, and enable rapid responses to customer demands. These systems are especially vital with the rapid growth of e-commerce and the increasing customer demand for same-day delivery for both direct-to-customer and B2B channels.
Several factors drive warehouses toward automation, including the need for faster product turnarounds, increasing SKU diversity amid rising warehousing costs, decreasing labor availability that hinders service levels, and increasing operational costs due to high wages. Whatever your operational or efficiency goals, pallet shuttle systems can help you meet and exceed them.
There are three main types of pallet shuttle systems. However, the foundational components of all three systems are the same. Every automated shuttle system consists of a rail system running through a multi-level storage racking system and a battery-powered intelligent pallet shuttle robot. The pallet shuttles glide along the rail to retrieve and store pallets as directed either by a forklift operator in the case of 1D shuttle systems or by a Warehouse Execution System (WES) teamed with a Robot Management System (RMS) for 2D and 3D shuttle systems.
Here's an overview of the three types of pallet shuttle systems to consider for your warehouse:
A 1D pallet shuttle, often called a "single-lane pallet shuttle," retrieves palletized goods within a storage rack system with multi-deep lanes. It operates in a single lane and is moved via forklift or pallet ASRS. These shuttles can run 24/7 with minimal downtime and reduce manual tasks, therefore reducing the need for a large workforce. They are ideal for tight areas where advanced automation may not be justified.
While 1D shuttle systems operate along a single path, 2D systems move automatically both horizontally between storage channels and depthwise within the rack structure. Some 2D systems stay within a specific storage level and aisleway, while others move between aisles and storage levels. They offer greater flexibility and are ideal for high turnover systems with high pallet movement rates. These systems are beneficial for warehouses with visibility to outbound retrieval foresight, enabling better load balancing during the put-away process.
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3D pallet shuttle systems are the most advanced. They can move in three dimensions: horizontally, depthwise, and vertically via lifts or ramps. These shuttles offer the highest degree of flexibility and storage optimization, making them ideal when outbound retrieval visibility is limited. Using built-in sensors, 3D shuttles can position loads intelligently, minimizing the risk of damage and injuries.
Consider 3D shuttles if your warehouse has complex and varied rack structures, or if outbound retrieval foresight is not possible. With fewer SKUs and many pallets, the need for using a 3D shuttle is reduced.
Choosing the right system begins with an assessment of your warehouse needs, including the flow of goods, storage density, outbound visibility, and inventory turnover rates. You should also consider your throughput, frequency of full pallet orders, and the complexity of your racking structures.
When searching for a warehouse pallet shuttle system, make a checklist based on your needs and operational parameters to find the best solution.
For instance, to maximize vertical space utilization and minimize labor requirements, consider a 2D or 3D pallet shuttle. If you're tight on space and budget, a 1D shuttle might be the most pragmatic solution.
Use the RightFIT seven-step methodology to determine your ideal warehouse shuttle system. Factors to consider include:
Your choice of warehouse shuttle system will have lasting impacts on your business, so choose carefully. Enlisting the services of an experienced order fulfillment and warehouse automation systems integrator can help you find the right solution. Even if you trust your internal team's evaluation skills, an outside perspective can be extremely valuable.
Investing in automated storage and retrieval systems will pave the way for true warehouse optimization. Schedule a consultation with Conveyco to start your warehouse automation journey. Contact us to discuss your requirements for a radio shuttle cart. Our experienced sales team can help you identify the best options for your needs.
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