The Faster and More Efficient Alternative to Traditional Storage and Retrieval Systems
The alternative to conventional storage and retrieval systems: Our Truck Shuttle system transports pallets to their storage locations faster and more efficiently than many traditional AS/RS such as stacker cranes. Initially, a vertical conveyor transports the pallets to the desired storage level. From there, one of our Truck Shuttles takes over, which can be deployed on multiple levels of a pallet warehouse. This compact vehicle functions as a storage and retrieval system, lifting and positioning unit and pallet shuttle all in one. It is capable of serving all channels on the storage level. The interplay of different storage levels with (often) reversible conveyor technology allows us to achieve maximum transport speed and system availability.
Simultaneous Storage and Retrieval on Each Storage Level
Our Truck Shuttle system is the core of our Automated Pallet Warehouse.
The basic idea: Several independent storage and retrieval systems automatically move the pallets in the storage aisles or the main aisle of the storage system.
Each rail-bound channel vehicle – which we call a Truck Shuttle – combines three functions in one carrier system: a lifting and positioning unit and a pallet shuttle. Truck Shuttles can be used on multiple storage levels.
Traditional storage and retrieval systems, such as stacker cranes, are not necessary. Instead, vertical conveyors transport the pallets via high-performance lifts to the desired levels.
The Alternative to Traditional Storage and Retrieval System
By deploying multiple Truck Shuttles on various storage levels, you achieve high technical redundancy in your pallet warehouse. For example, pallets of the same batch can be distributed across several levels, allowing direct access without wait times or detours.
The compact vehicles are equipped with energy-optimized drives, acceleration requires significantly less power than conventional storage and retrieval systems.
Multiple Truck Shuttles for Optimized Material Flow
With our Truck Shuttle system, you can significantly optimize the transport or output performance of your Automated Pallet Warehouse – just four of our devices can achieve up to 140 cycles per hour.
For even higher storage performance, you can deploy up to two Truck Shuttles on one level.
Combined with our high-performance vertical conveyors, the storage pallets can be quickly and securely distributed to the corresponding storage levels, maximizing system performance and flexibility.
Key Features at a Glance
- High system availability with the use of one or more storage and retrieval systems (Truck Shuttles) per storage level
- 25-35 individual cycles per hour per storage level and Truck Shuttle
- Pallet shuttles designed for standard pallet weights up to 1,500 kilograms
- 70-170 pallets per hour per vertical conveyor
- 3 m/s speed in the main aisle per storage level
- 0.5 m/s storage and 0.7 m/s retrieval speed (without pallet)
- Power supply via rail (truck) and cables or power caps (shuttle)
Functionality of a Storage and Retrieval System
In many pallet warehouses, rail-bound storage and retrieval systems (AS/RS) handle the automatic storage and retrieval of pallets and goods. There are single-mast stacker cranes for light loads and double-mast AS/RS, which can handle heavier loads thanks to the second mast.
Mast devices typically operate in a storage aisle and are guided on rails at the floor level – rarely within the storage systems themselves. One rail is often anchored in a floor slab, while the second, upper guide rail is attached directly to the rack. This rail guidance ensures stability for pallet transport within the warehouse to the storage locations.
Distinctive Features of Our Solution Compared to Traditional Storage and Retrieval Systems
Our Truck Shuttle system offers several advantages over conventional single-mast or double-mast storage and retrieval systems in logistics operations. Key benefits include:
Higher Performance, Lower Risk of Downtime
While conventional single-mast or double-mast storage and retrieval systems can deliver high performance in storage levels, they rely on a single unit, which often requires high maintenance. If this device fails, it can disrupt or halt the entire warehouse operation. Additionally, the systems are large and heavy, which requires reinforced floors, which in turn means higher costs, more challenges in getting a permit and longer construction time.
Higher performance and lower risk of downtime can be achieved with multiple storage and retrieval systems and storage aisles, significantly impacting the initial investment as well as the running energy and maintenance costs.
Vertical Conveyors Instead of Mast Devices
An alternative for vertical transport with mast devices or stacker cranes are our vertical conveyors. Similar to elevators, they can easily access multiple heights, automating the flow of goods on a vertical level and opening up additional potential for space utilization in the warehouse.
Higher Energy Efficiency than Mast Devices
Our Truck Shuttles are lighter and more energy-efficient compared to other storage and retrieval systems: The electrical consumption during storage or retrieval is only 0.02 kWh per cycle. Even in 24-hour operation and under deep-freeze conditions, all efficiency and reliability requirements are met.
Robust Machinery
The components used in our Truck Shuttles are brand-name, industry-standard products from local manufacturers, the structures are made of welded steel, the system can therefore be easily maintained and serviced by technicians.
Reduced Fire Load for Round the Clock Operation
By eliminating high-voltage batteries, our Truck-Shuttle system significantly reduces fire load. Power can be supplied via cable, which not only results in lower insurance premiums for the entire warehouse but also enables true 24/7 operation – even under deep-freeze conditions.
Plan for Depth Instead of Height
Permits are usually required in order to build enclosed steel structures higher than 10 meters. The regulations call for sprinkler systems and other advanced safety features are also needed for the operation of large mast devices. Additionally, high-rise steel construction, as often seen in large silos, may not always work in other kinds of buildings with unique architecture.
Today, whoever is thinking about an automatic high-bay warehouse with double-depth storage should consider an Automated Compact Warehouse or high-performance channel storage system with Truck Shuttles as an alternative. Our storage system comprising a low steel structure requires less clearance compared to a high-bay warehouse. Moreover, a channel storage system with handling devices on each level can achieve the same capacity as storage and retrieval systems but with more energy efficiency.
Mixed Pallet Storage Possible
When different pallet types need to be stored – such as industrial and Euro pallets – mast systems and other AS/RS create homogenous batches. Keeping the pallet sizes and types grouped together is often necessary to ensure trouble-free operation.
With our Truck Shuttle system, pallets do not need to be stored by type. It allows for precise storage of a mix of Euro pallets, industrial pallets, and plastic pallets.
Safe Access for Inspections and Troubleshooting
Traditional mast and storage and retrieval systems reach high speeds and can be used at rack heights over 40 meters. Due to the high acceleration of the AS/RS, warehouse safety is mandatory, warehouse personnel cannot safely enter the storage aisles.
In our Truck Shuttle system, individual storage levels can be shut down separately, ensuring safe access during service and maintenance hours, while operation can continue on other levels.
Multiple Storage and Retrieval Systems with High Travel Speeds
The travel and lifting speeds of an AS/RS in a high-bay warehouse depend on the type of transport goods, the lifting height, and the turnover rate.
Each Truck Shuttle in our storage system achieves high travel speeds thanks to electric drives with frequency control, with speeds of 3 m/s in the main aisles and 0.5-0.7 m/s in the channels. The lifting mechanism has a mechanical drive.
