Shuttle Pallet Racking

The AR Shuttle is a compact semi-automated pallet storage system that uses motorized satellite vehicles to transport, deposit, and retrieve pallets autonomously within the storage channels. The operator places the satellite vehicle and the load at the channel entry using a forklift, then uses a radio-control handset to instruct the vehicle to carry out loading, unloading, or compaction operations. This reduces the need for the forklift to enter the racking structure and improves overall storage density.

Unlike drive-in rack, in the AR Shuttle system the forklift does not enter the internal aisles of the structure — the satellite vehicle handles all pallet movement within the channels. This significantly reduces the risk of impacts and structural damage. The system also allows a different load to be stored on each level, and can improve operational throughput by overlapping satellite and forklift movements during consecutive loading or unloading tasks.

Yes. The AR Shuttle can be configured for LIFO operation, with loading and unloading from the same face, or for FIFO operation, with loading and unloading from opposite ends of the channel. The chosen configuration is defined during the project design phase based on the operational requirements and the rotation logic applicable to each product line.

This flexibility makes the system suitable for a wide range of applications, from cold storage facilitys with strict rotation requirements to ambient distribution with variable SKU turnover. 

The pallet shuttle system AR Shuttle is particularly well suited to cold storage facilitys and freezer environments because of its high compaction, which reduces the refrigerated volume and improves energy efficiency. The satellite vehicle is designed to operate reliably at low temperatures, including in deep-freeze conditions.

Reducing the time that operators spend working inside the cold storage facility is an additional benefit, as the forklift only needs to access the aisle entry rather than traveling deep into the structure.

Under normal operating conditions, the satellite will not start a mission if the battery level is below the defined minimum safety threshold. However, in the unlikely event of a battery failure during operation, the vehicle is designed to hold its position safely within the channel. A rescue procedure using the forklift can then retrieve the satellite.

The lithium battery management system continuously monitors charge levels and provides alerts to the operator before the threshold is reached.

A single operator can manage several satellite vehicles from the radio-control handset, with a standard configuration allowing control of up to three units. This enables efficient use of the operator’s time, particularly in large installations where multiple channels are being loaded or unloaded simultaneously.

The AR Shuttle incorporates safety systems designed to protect both the operation and personnel. These include end-of-channel detection sensors to prevent the vehicle from traveling beyond the channel limits; anti-collision detection; battery level monitoring with low-charge warnings; and position feedback to the control handset. The system is also designed to hold its load safely in the event of a power interruption.

The AR Shuttle can coexist with a WMS-managed warehouse, but the satellite handset operates independently from the warehouse management software. The operator receives task instructions from the WMS in the usual way, and then uses the handset to direct the satellite vehicle accordingly.

For fully integrated automation — where the satellite movements are controlled directly by the WMS or a WCS — a higher level of system integration is required, which should be assessed during the project design phase.

Each AR Shuttle unit is designed to handle loads of up to 1,500 kg as standard, with versions available for loads up to 2,000 kg depending on the project specification. Travel speed within the channel is optimized to balance throughput with safe and controlled pallet movement.

AR Racking defines the appropriate satellite model and channel parameters during the engineering phase to ensure performance targets are met.

An existing drive-in installation cannot be directly converted to an AR Shuttle system without a thorough structural and dimensional review. The two systems have different structural requirements, rail profiles, and clearance tolerances.

In some cases, a partial reuse of existing structural elements may be possible, but this must be assessed on a project-specific basis by AR Racking’s engineering team.

The AR Shuttle is a semi-automated system, not a fully automated solution. Its level of automation is limited to the movement of the satellite vehicle within the channels; the forklift and operator are still required for channel entry, satellite repositioning, and all interface tasks.

However, the system can be a stepping stone towards greater automation. With the appropriate structural design and layout planning from the outset, it is possible to evolve the installation towards higher levels of automation.

The AR Shuttle is available in a wide range of sizes and can be adapted to suit different pallet dimensions. The critical requirement is that pallet dimensions and tolerances are clearly defined during the project design phase, so that the channel geometry, rail spacing, and satellite model are correctly specified.

Pallets with irregular or poorly conditioned bases may cause handling issues and should be assessed individually.

There is no single depth limit defined solely by the satellite vehicle. Channel depth is determined by the height of the building, the number of pallet positions required, the load weight, the forklift reach, and the operational requirements of the project.

AR Racking designs channel depth and height as part of the overall project layout to balance density, throughput, and operational efficiency.

The AR Shuttle’s lithium battery reaches full charge in approximately six hours and provides up to eight hours of operational autonomy under typical working conditions. For continuous operations, it is advisable to have a spare battery available so that the satellite can return to service immediately after recharging.

The battery management system monitors charge levels in real time and alerts the operator when charging is needed, preventing unplanned downtime.

Before defining an AR Shuttle project, AR Racking analyzes the client’s operational requirements in detail: unit load type and dimensions, number of SKUs, rotation frequency, daily throughput targets, building dimensions, and any specific environmental or temperature requirements. This analysis is used to define the optimal number of satellites, channel depth and height, layout configuration, and the most appropriate FIFO or LIFO logic for each product zone.

AR Shuttle installation is planned in a modular way, and where the warehouse layout and operational activity allow, phased installation is possible to minimise disruption. Zones can be commissioned progressively while other areas of the warehouse remain operational.

AR Racking’s project management team works with the client to plan the installation sequence and minimise downtime during the transition period.

As part of the project handover, AR Racking or its accredited partners can provide on-site training to operators and maintenance personnel. Training typically covers radio-control operation, mission programming, battery management, basic troubleshooting, and safety procedures.

The system is designed to be intuitive to operate, and most operators reach proficiency within a short familiarisation period.

The AR Shuttle control handset displays operational information including battery status, mission status, position within the channel, and basic fault alerts. This allows the operator to monitor the vehicle’s condition and identify any issues during normal operation.

For more advanced monitoring and integration with warehouse IT systems, additional diagnostic tools and data interfaces can be specified as part of the project scope.

The AR Shuttle does not impose floor requirements beyond those of other conventional storage systems. The structural tolerances for the racking are calculated in accordance with ANSI/RMI MH16.1 (or the equivalent international standard EN 15512), and the rail installation for the satellite vehicle is specified to ensure accurate and reliable movement within the channels.

The satellite vehicle requires preventive maintenance of its critical components, including sensor cleaning, battery and charging system checks, wheel and drive mechanism inspection, and verification of the electronic control systems. The maintenance schedule is defined by AR Racking and should be followed to ensure reliable long-term performance.

The ROI for an AR Shuttle project is calculated primarily on the basis of operational savings and performance improvements compared with the previous storage solution. Key factors include the increase in storage capacity per square metre, the reduction in forklift movements and operator time, energy savings (particularly in cold storage facility applications), and the reduction in product damage.

AR Racking can provide a project-specific ROI analysis during the pre-sales phase, using the client’s operational data to model the expected benefits.