Automated Storage & Retrieval Systems (AS/RS) | Automated Pallet Shuttle Solutions
Transform your warehouse operations with our automated storage and retrieval system (AS/RS) solutions featuring the Interlake Mecalux Automated Pallet Shuttle. Our AS/RS storage systems combine compact racking with automated handling equipment—stacker cranes and transfer cars—to dramatically boost capacity and productivity. The pallet shuttle system eliminates forklift dependency, reduces labor costs, and maximizes every cubic foot of your facility. Whether you operate ambient, refrigerated, or freezer warehouses, our automated pallet racking systems deliver unmatched throughput with the utmost safety for operators and inventory.
How the Automated Pallet Shuttle Works
Our AS/RS automated pallet shuttle system combines compact storage with automated handling for maximum throughput:
- Pallet Loading: Pallets enter the AS/RS system at designated entry points. The stacker crane or transfer car picks up the pallet along with the motorized shuttle in its cradle.
- Automated Transport: The stacker crane travels along the aisle to the designated storage channel, positioning the shuttle and pallet at the correct level and location.
- Shuttle Insertion: The electric pallet shuttle is inserted into the storage channel, where it autonomously places each pallet in the deepest available position for maximum density.
- WMS Integration: All operations follow orders from the Easy WMS Warehouse Management System, ensuring precise inventory tracking and optimized storage assignments.
- Retrieval: For outbound operations, the process reverses—the shuttle retrieves the designated pallet and returns it to the stacker crane or transfer car for delivery to pick stations.
This fully automated process eliminates forklift dependency, maximizes storage density, and increases throughput by up to 300% compared to conventional compact storage systems.
AS/RS System Variants: Stacker Crane vs. Transfer Car
Choose the right automated pallet shuttle configuration based on your throughput and capacity needs
Automated Pallet Shuttle with Stacker Crane
The stacker crane transports pallets from AS/RS entry and exit points to any storage channel. Two high-density racking units are installed on each side of the working aisle, with aisles less than 63" wide and storage heights over 131'. Integrated with Easy WMS for precise stock control and maximum cycles per hour.
Automated Pallet Shuttle with Transfer Car
Transfer cars operate on each level with guide rails, using lifts for vertical movement. The number of cycles per hour is multiplied by the number of levels, making this the most efficient compact storage system for combining high capacity with high throughput. All management is handled by Easy WMS.
Automated Pallet Shuttle Technical Specifications
Key technical data for the Interlake Mecalux automated pallet shuttle system
| Pallet Width | 47.2" |
| Pallet Depth | 31.5" / 39.4" x 47.2" |
| Load Capacity | Up to 1.65 tons |
| Wheels | 8 |
| Travel Speed (No Load) | Ambient: 361'/min · Cold: 249'/min |
| Travel Speed (With Load) | 230'/min |
| Lift Time | 2 seconds |
| Operating Temperature | Ambient: 41–113°F · Cold: -22–41°F |
| Battery | Supercapacitors (auto-charging) |
AS/RS Advantages vs. Disadvantages
Advantages
- ✓Maximum Storage Density: AS/RS racking achieves the highest possible storage density with channels up to 131' deep, utilizing every cubic foot of your warehouse.
- ✓Dramatic Productivity Increase: Automated pallet shuttle systems deliver a major increase in cycles per hour compared to manual or semi-automated storage systems.
- ✓Reduced Labor Costs: Goods-to-person automation eliminates manual forklift operations, reducing staffing requirements by up to 80%.
- ✓Energy Savings: Especially impactful in cold storage—AS/RS reduces the volume that needs cooling and eliminates operator exposure to extreme temperatures.
- ✓Enhanced Safety: Fully automated operations remove personnel from high-rack areas, reducing workplace injuries and improving OSHA compliance.
- ✓Scalable Configurations: Choose stacker crane systems for standard throughput or transfer car systems that multiply cycles per hour by the number of levels.
Disadvantages
- ✗Higher Initial Investment: AS/RS systems require significant upfront capital compared to conventional racking—typically justified by 3-5 year ROI through labor and energy savings.
- ✗Complex Installation: Automated systems require specialized engineering, floor preparation, and integration with WMS software.
- ✗Maintenance Requirements: Stacker cranes, shuttles, and control systems require scheduled preventive maintenance by trained technicians.
- ✗Limited SKU Flexibility: Best suited for operations with medium to high consumption SKUs; not ideal for highly diverse, low-volume inventory profiles.
AS/RS Automated Pallet Shuttle Key Features
Why leading warehouses choose automated storage and retrieval systems
- •Maximum space savings: AS/RS racking with storage channels up to 131' deep and racking over 131' tall for unmatched warehouse density
- •Rapid shuttle movement: Electric pallet shuttle reduces goods entry and exit times, dramatically increasing cycles per hour
- •Goods-to-person system: Loads move automatically to pick stations, eliminating manual forklift travel
- •Supercapacitor charging: Shuttle charges automatically while onboard the stacker crane or transfer car—always ready to operate
- •Cost savings: Reduces handling equipment, surface area, staffing, and energy costs—especially in freezer warehouses
- •Flexible configurations: Multiple setup options based on SKU count, pallet quantity, and required movement rates
- •Operator safety: Compact AS/RS with pallet shuttle ensures maximum safety for staff, loads, and the system itself
Common AS/RS Design Questions
Help us design the perfect automated storage and retrieval system for your facility
- •What is the available warehouse area and clear ceiling height for the AS/RS system?
- •What are the dimensions and weight of your standard pallets?
- •How many SKUs do you need to store, and what is the quantity per SKU?
- •What are your required inbound and outbound pallet movements per hour?
- •Is this an ambient, refrigerated, or freezer warehouse environment?
- •What is your current WMS system, if any?
- •What is your estimated project timeline and budget range?
Frequently Asked Questions
Common questions about Automated Storage & Retrieval Systems (AS/RS)
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