Pallet Shuttle Systems
Pallet Shuttle Systems
Your First Step Toward Warehouse Automation — Semi-Automated Pallet Shuttle Systems That Scale
High-density, semi-automated pallet shuttle racking that increases storage capacity, reduces forklift travel, and boosts throughput without the cost and complexity of a full AS/RS. Storage Coordinators designs, installs, and supports Pallet Shuttle systems for ambient and cold-storage facilities across the Mid-Atlantic and beyond.
What is a pallet shuttle system?
A pallet shuttle (also called radio shuttle, pallet runner, or pallet mole) is a semi-automated deep-lane storage solution. A battery-powered cart rides on rails inside the rack to move pallets to and from the pick face while the lift truck remains at the aisle, reducing travel distance, rack damage, and congestion.
Automha’s Pallet Runner™ platform is the category’s original. Invented, patented, and launched in 1999, now with 11,000+ shuttles installed in 65+ countries.
Pallet Shuttle Benefits & Features
- Maximize Density – Maximize density. Achieve lane depths unattainable with traditional racking while maintaining selectivity.
- Increase throughput – Up to 25 pallets/hour per shuttle in typical operations.
- Ambient to deep-freeze – Reliable performance from +113 °F to −25 °F.
- Safer, fewer rack entries – “Drive-in without driving in”; cut travel and impacts while meeting modern fire-suppression/flue-space practices (e.g., 6″ longitudinal flues).
- Smart functions – Continuous load/unload, Compacting, Inventory Count, Multi-Cart anti-collision, Multi-Pallet handling, and more.
- Energy-efficient Lithium ion – Fast, simple battery swaps (5-hour recharge)
- Scale on your terms – Start with semi-automation; add Wi-Fi control, AGVs, or cranes later.
How Pallet Shuttles Work
- Position the shuttle. The forklift operator places the Pallet Runner™ at the lane entrance (“Home” position).
- Command the cycle. Using the handheld RF remote (or optional Wi-Fi control), the operator selects Load or Unload mode.
- Automated travel. The shuttle transports pallets deep into or out of the lane, stopping precisely at each storage position.
- Return to Home. After completing its task, the cart automatically returns to the lane entrance for the next command.
- Advanced modes for efficiency. Use Continuous Load/Unload to process multiple pallets in sequence, and Compacting Mode to close gaps between loads and optimize storage density.
The result? Less forklift travel, safer operations, reduced rack damage, and higher throughput compared to drive-in or pushback systems.
Typical Storage Applications For Pallet Shuttle Systems
Check out some common pallet shuttle applications below:
- Cold storage & food (deep-freeze, blast freezers).
- High pallets per SKU / low SKU count.
- Truckload staging in shipping/receiving.
- Non-stackable products and high utilization targets.
- Labor-intensive applications
- Fast throughput
- Clients looking to maximize storage density
- Clients looking to increase productivity
REQUEST A QUOTE
Maximize Storage. Reduce Travel. Increase Throughput. Get a custom pallet shuttle system design tailored to your pallets, throughput, and facility layout.
Pallet Shuttle System
Pallet Runner™ Specs at a glance
| Attribute | Pallet Runner™ GTR |
|---|---|
| Load capacity | 3,300 lb (standard); 4,400 lb heavy duty |
| Operating temps | +45 °C to −30 °C (−22 °F) |
| Throughput | Up to 25 pallets/hour per shuttle (application-dependent) |
| Power | 48 V Lithium-ion, ≈5 hr recharge |
| Comms | RF standard; optional Wi-Fi (2.4/5 GHz) |
| Functions | Continuous load/unload, Compacting, Inventory Count, Multi-Pallet, Multi-Cart anti-collision |
| Safety | E-stop, impact bumpers, optional laser scanners; anti-fall fork magnets |
| Pallet spacing | Adjustable 0.8″– 6″ inches |
| Integration | AWMS software, AGV interface, WMS/Wi-Fi control |
FIFO, LIFO, mezzanine buffer & case-picking modes
Pallet Shuttle systems ensure optimal inventory turnover, which is essential for handling perishable or short-term products. The first package placed is the first to be picked, ensuring that older products are used first. This not only reduces waste, but also improves the efficiency of the flow of materials in the warehouse.
Shuttle systems also allow you to efficiently manage products that do not require frequent rotation. This is especially useful for warehouses that process non-perishable materials or that have longer life cycles. The first pallet inserted is the last to be picked, ensuring that older products are used first, reducing access time to recently stocked products and optimizing warehouse space.
Takes care of the storage of pallets above the warehouse flow, without sacrificing selectivity. This solution will optimize the use of available space in the warehouse, the loading of trucks will be improved and in turn, reduce transport times.
Carts move pallets to the upper levels of the warehouse to optimize the work of the picking aisles in the lower levels. The activity takes place inside a tunnel that crosses the racking parallel to the base. An efficient and space-saving way to store pallets in close proximity to the picking point, while at the same time achieving a safe picking lane.
Pallet Runner™ GTR vs. Others (overview)
| Feature | Pallet Runner™ GTR | Others |
|---|---|---|
| Max capacity | Up to 4,400 lb (HD) | Up to 1,800 kg (3,968 lb) |
| Operating temps | +45 °C to −30 °C (−22 °F) | −30 °C to +40 °C |
| Wireless control | RF standard; Wi-Fi option with AWMS | Remote control; dealer-network support |
| Advanced functions | Continuous PLUS, Compacting (push/pull), Inventory Count, Multi-Cart anti-collision | Semi-automated load/unload (functions vary by deployment) |
Safety, service & uptime
E-stop, safety bumpers, optional dual laser scanners, fork anti-fall magnets, and status LEDs.
Battery certifications: Lithium ion packs tested to IEC 62619, IEC 62133, UN 38.3.
Parts, overnight shipments, phone/remote diagnostics, on-site repairs, PM programs, and rental carts for peak season.
What we need to engineer your system
- Pallet dims/weight/overhang & load description
- Throughput (inbound/outbound), SKU count, FIFO/LIFO flow
- Operating temp; forklift lift height; photos/layouts (DWGs)
- Stakeholders & project timing/funding
- We’ll model density, labor impacts, and ROI and properly size cart quantity to your peaks.
Results you can expect
Up to 50% more storage utilization in the same footprint when moving from selective or drive-in racking to deep-lane pallet shuttle systems (application-dependent).
Lower forklift travel time — reduces operator fatigue, increases throughput, and cuts labor costs.
Less rack damage thanks to “drive-in without driving in” operation.
Improved safety by minimizing forklift traffic inside racking lanes.
Lower facility operating costs with fewer aisles to heat, light, and maintain.
FAQs
A semi-automated deep-lane storage solution where a battery-powered cart moves pallets inside the rack, reducing forklift travel, rack damage, and congestion while increasing storage density.
