Shuttle Rack D3 — Multi-Deep Pallet Storage System

Shuttle Rack D³ (pronounced "D-three") is an automated warehouse that achieves ultra-high density pallet storage. It is ideal for the storage of large-lot products and raw materials such food, beverages, and chemicals. The system allows for significantly better use of floor space compared to conventional, manual approaches where pallets are stored flat or stacked on warehouse floors.

Automating storage and retrieval allows for a significant reduction in forklift operations, as forklift operators no longer have to move around the warehouse shifting pallets or looking for products.

System Configuration

The D³ system consists of receiving/unloading conveyors, vertical lifters, a pair of parent and child shuttles per layer, and storage lanes which accommodate one lot per lane. The system uses a dedicated wireless LAN to communicate with the control PC. Each parent and child shuttle pair works together in real time to ensure smooth loading and unloading operations. The child shuttle is equipped with a lithium-ion battery, which is automatically recharged on the parent shuttle.

Storage and retrieval conveyor + lifter
Parent and child shuttles
Storage lanes

Layout Variations

The warehousing/unloading station layout is flexible and can be adjusted according to the building configuration and work lines. In addition, depending on the required storage volume and processing capacity, the system can have racks on both sides of the travel lane.

First-In Last-Out model (FILO)

One-Side FILO : The storage rack is placed on one side of the shuttle travel lane.
Double-Side FILO : Storage racks are placed on both sides of the travel lane, with shuttles able to access both sides.

First-In First-Out Model (FIFO)

By providing a shuttle lane on both sides of the storage rack, it is possible to ship loads coming in from the production line to the shipping berth in FIFO order. In addition, installing a dedicated retrieval conveyor and lifter on the production line side facilitates the retrieval of pallets for sample tests or to feed work-in-process (WIP) items to the production side again.

Model System

Finished Product Warehouse for Beverage Factory

In the soft drink manufacturing industry, the top SKUs often account for about 80% of the total volume, and the amount of inventory per SKU is higher than in other industries. The Shuttle D³ is the ideal fit for this kind of small-mix, high-volume storage need.

In the above model system, beverage product cases transported from the production lines are stacked on pallets by a layer palletizer (1), and then entered into the D³ (4) via a pallet conveyor (2) and a high-speed rail-guided vehicle STV (3). Pallets that have been ordered for shipment are sent out from the D³ via an STV to the truck berth side conveyor (5). Stacked, empty pallets returned to the site are fed from the truck berth side conveyor (6) through the STV to the layer palletizer. Combined with other material handling equipment, the D³ provides high-level automation from production to shipping.