Shuttle System
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
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
| 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 |
| Shuttle Speed | |
| 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
Application Industry
Cold storage, freezers, frozen foods
Pharma and medical product warehousing
Beverage and food distribution centers
E-commerce & retail buffer storage
High-volume, low-SKU pallet storage
