Shuttle System

The STALWART Manual Shuttle Racking System is a non-automated high-density storage solution where pallets are moved inside the lane using a mechanical shuttle carriage operated by a forklift.

The shuttle carries the pallet and is pushed or pulled manually along guide rails.
Forklifts do not enter deep inside the rack, improving safety compared to Drive-In systems.

✔ No motors
✔ No electrical components
✔ Lower cost than automated shuttle systems

Category: Racking System

Key Features

High-Density Storage: Eliminates forklift drive-in aisles inside racks, enabling deeper lanes and increased capacity
Shuttle-Based Automation: Battery-operated shuttle places/ retrieves pallets from channel depths, controlled by remote or WMS
LIFO/FIFO Configuration: Supports LIFO (single-sided) and FIFO (double-sided entry) operations
Safety Advantages: Forklifts stay outside lanes, reducing risk of rack damage
Cold-Storage Friendly: Shuttles operate in freezer conditions with long battery life
Flexible Layout: Channels of various depths (2–10 pallets) and multi-tier options possible

Sizes Available

Shuttle Speed
Width (Beam)	1300mm to 3000mm
Height (Upright)	3000mm to 9000mm
Depth (Decking Panel)	800mm to 1200mm
Levels	As per Client Requirement
Load Capacity	1000kg to 5000kg UDL
Shuttle Battery Run-time	Up to 10 hours
Load Capacity / Shuttle	1500 kg per shuttle unit

Basic Elements

Component	Available Sizes / Type	Usage
Upright Frame - 20 Fold	80x65mm, 100x65mm, 110x65mm, 130x65mm	Main vertical structure bearing vertical loads
Beam (Box Type) - 34 Fold	90x50mm, 100x50mm, 110x50mm, 120x50mm, 140x50mm, 160x50mm	Horizontal load-bearing member where pallets sit
Beam Bracket	2/4-hook adjustable plate	Connects beams to uprights with high strength
Shuttle Carrier	Custom width to bay; height approx. 250–300 m	Autonomous pallet placement/extraction
Shuttle Drive Wheels	Ø200–300 mm hardened steel	Moves shuttle along floor rails
Pallets	1200x800 mm, 1200x1000 mm, 1000x1000 mm	Goods platform used for forklift handling and placement on racks
Pallet Support Bar	size ?	Prevents pallet sag, placed between beams
GI Decking Panel - Multi Bend	If Require	If require
Horizontal & Diagonal Bracing	35 x 15mm, 35 x 18mm, 35 x 25mm, 35 x 31mm	Rack stability and sway control
Base Plate	120x120 mm or 150x150 mm with anchor holes	Anchors upright to floor for structural stability

Accessories

Row Spacer	200 mm, 300 mm	Maintains uniform spacing between back-to-back rows
Beam Locking Pin	Spring or pin type	Prevents beam from accidental dislodgement

Safety Elements

Column Guard / Upright Guard	400 mm H / 500 mm H / Wrap Type	Protects upright base from forklift impact
Row End Guard	Wrap-around or bolt-on	Prevents forklift damage at row ends
Top Cap (Optional)	Plastic or MS cap	Protects upright tops; adds a clean finish
Side & Back Cladding (optional)	Plain Sheet or perforated	Prevents item fall-through; adds rigidity

Operating Flow (Example – LIFO Mode)

Forklift places shuttle at channel entrance.
Pallet is set on rails atop shuttle.
Operator activates shuttle via tablet.
Shuttle lifts pallet slightly and moves it to first available position.
Shuttle returns empty to entrance.
Upon retrieval, the process is reversed.
FIFO requires entry/exit from opposite ends

Shuttle Storage Rack Manufacturers for Seamless Operations in Your Industry

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