Pallet Shuttle

Pallet Shuttle

Semi-automatic compact system that uses an electric shuttle to load and unload the pallets inside shelves quickly and accurately.

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The Product

A compact storage system in which a shuttle, driven by an electric motor runs on rails inside the storage channels, replacing forklifts, considerably reducing operating times and enabling items to be grouped by channel rather than in complete lanes.

The Pallet Shuttle follows orders sent by an operator using a tablet with WiFi connection, depositing the load in the first free placement location in the channel and compacting the pallets as much as possible. By removing the need for forklifts to enter the lanes, storage capacity is increased in terms of depth, the risk of accidents and damage to the racks is negligible, operator movements are optimized and warehouse operation is modernized and made more flexible.

It is an ideal solution for companies with a high volume of pallets per item and intensive loading and unloading activity.


  • Greater diversification: each channel can be used to store a different item.
  • High productivity: increased flow of incoming and outgoing goods.
  • Greater capacity: Storage depth of up to 131 feet.
  • Highly cost-effective, thanks to the reduction in operating costs.
  • Decreased incidents and maintenance costs.
  • Many advanced functionalities can be easily controlled from the tablet.


Technology applied at top operating speeds

Save space

  • Increased number of pallets in depth: Storage channels can exceed 131 feet in height; the maximum height is determined by the handling equipment used.
  • The system works with minimal clearances between levels, which allows for high-density storage.
  • Through the use of sensors the shuttles can position loads intelligently, eliminating empty spaces in the storage lanes. As a result, the effective capacity of the warehouse (which takes into account flows of goods in and out of the warehouse) reflects its physical capacity.

Save time

  • Loading and unloading times are reduced, since the operator does not need to move around inside the lanes.
  • The shuttle can travel at a speed of 295 ft/min when empty, or 148 ft/min when loaded.
  • Load lifting cycle of just 2 seconds.
  • With just a single command, the shuttle can progressively fill or empty a whole lane.

Increased productivity

  • Increased flow of goods in and out of the warehouse.
  • Unlike conventional drive-in systems, items can be grouped by channel, rather than requiring a full lane, thereby allowing for greater diversification.
  • Optimization of operator movements, using the product-to-person system: It is the load that moves to the operator.
  • While the Pallet Shuttle carries out a command, the operator collects another pallet, thereby achieving continuous movement.
  • Depending on temperature and load conditions, the shuttle has an operational range of up to 10 hours working at full throughput.
  • The lithium batteries are easily accessible and have fast connections that eliminate the need for wires, so that they can be changed quickly without interrupting the operation cycle.
  • Elimination of errors.
  • The system is easy to use and easy to maintain.
  • A single tablet can control up to 18 shuttles.
  • Inventory function: The shuttle counts the number of pallets stored in a channel.

Cost savings

These benefits, allied to its efficient use of energy, lead to immediate cost savings, making the Pallet Shuttle one of the most cost-effective compact storage systems available.


  • The shuttle has built-in sensors that enable different types of pallets to be detected and handled.
  • The Pallet Shuttle models 4048 and 4840 can work with pallets of different widths and sizes. The 4048 model can be used to handle pallets 40 inch deep ( and around 48 inch front). The 4840 model can be used to handle GMA pallets, 48 inches deep.
  • All shuttles can operate in LIFO or FIFO mode. The operator uses the tablet to select the mode he/she wishes to work with.
  • The shuttle platform is designed to carry pallets that have a maximum buckling limit of 1 inch.
  • Any type of forklift can be used to handle the shuttle.
  • Up to 3,307 lbs per pallet can be handled.
  • It is possible to install Mecalux's Warehouse Management Software Easy WMS on a tablet.
  • The system is scalable. There is an easy option to increase the number of shuttles as the need to increase productivity arises.
  • Versatility


  • Thanks to the way that the structure is built, and given that forklifts do not need to drive into the lanes, the risk of accidents is practically non-existent and the metallic structure is not damaged, thereby keeping maintenance to a minimum.
  • There is a user management feature that prevents unauthorized personnel from using the shuttles.
  • Both the racking and the shuttles have built-in safety features specifically designed to ensure the correct operation of the Pallet Shuttle system: rail end stops, pallet centralizers, position sensors, etc.

Mecalux Guarantee

Interlake Mecalux designs and manufactures all the component parts of the Pallet Shuttle compact storage system, including the special racking structure to ensure optimal movement of the shuttles. The company also manufactures its own shuttles.

This guarantees perfect operationand a perfect fit for all the different elements of the system, as well as their quality and compliance with the safety regulations in force in each country.

Thanks to the resources invested in R&D&I, Mecalux’s Pallet Shuttle includes the latest technological innovations, offering optimal performance at a very competitive price. It has innovative features, including remote control via tablet, the positioning camera and the safety scanner. It is also one of the fastest systems on the market and can be adapted to the specific needs of any warehouse, making it even more efficient.

Interlake Mecalux provides a warranty of five yearsfor the Pallet Shuttle racking structure, of one year for the operation of the shuttle, and of six months for the operation of the batteries.



A way of quickly and frequently transporting pallets back and forth

According to the dictionary definition, a shuttle is a vehicle that travels to and fro between fixed points at frequent intervals. Mecalux’s Pallet Shuttle fits this description perfectly, with the journey being from the rack’s P&D station to the first available space in the storage channel, and back again (or vice versa, for unloading).

Eventually the evolution of compact storage systems raised the following question: Why not make it a motorized shuttle, instead of a forklift, that enters the storage channel to handle the pallets, increasing loading and unloading speeds and optimizing the effective capacity of the warehouse?.

The smart answer was the Pallet Shuttle: The racking structure is adapted so a shuttle with an electric motor can move along the inside of storage lanes on a track, following the commands given by the operator using a WiFi tablet.

The forklift just leaves the load on the track, and the Pallet Shuttle picks it up and moves it independently, storing it in its placement location while keeping the pallets as compact as possible. By removing the need for forklifts to enter the lanes, handling times are reduced, storage capacity is increased in terms of depth, the risk of accidents and damage to the metal shelves is negligible, operator movements are optimized and warehouse operation is modernized.

This is how the Pallet Shuttle system offers a compact storage solution that reduces operating costs and improves performance in the supply chain. Making progress the smart way.

Example of a compact warehouse with Pallet Shuttle

In Action

Compact semi-automated warehouse with Pallet Shuttle

In semi-automated installations, operators only need to handle the forklifts that carry the pallets and initiate the motorized shuttle’s activity. The movement of the shuttles inside the racking is automated.

  • Step 1

    A forklift places the Pallet Shuttle in the channel where work is to be done.

  • Step 2

    Next, the forklift is used to position pallets one by one in the channel entrance, resting them on the load-bearing beams.

  • Step 3

    Using the tablet, the operator sends the command to the shuttle to start the loading operation. Once the location of the pallet has been identified, the Pallet Shuttle lifts the pallet slightly above itself and moves it horizontally until it reaches the first available location, where it deposits the pallet. Different sensors accurately control the movement of the load being stored.

  • Step 4

    The Pallet Shuttle returns to the beginning of the lane in order to repeat the operation with the next pallet, and so on, as many times as necessary until the channel is filled. Before the last position is filled, the shuttle is removed and the sequence is repeated in the next channel where work is required.



Safety and control: The foundations on which the system is built

In addition to the control tablet that transmits orders to the shuttle over WiFi, the system consists of two basic components:

The rack structure

  • Upright

    They are the vertical components that can be adapted to a wide range of load requirements.

  • Beam

    They are the horizontal, robust racking components where loads are deposited.

  • Rail

    The Pallet Shuttle runs on rails inside the storage channels. Its design facilitates loading and keeps the shuttle centred.

  • External rail supports

    These are used to fix and anchor the rail at each load level to the entry/exit frame's outer upright.

  • Inner rail supports

    These fix the rails to the beams on all points except at the channel's entry and exit.

  • Rail-end stop

    Made of folded sheet metal, in a 5 or 8-mm thick L-shape, these are used as a detection element to slow and stop the shuttle in normal working conditions.

  • Pallet centraliser

    These are fitted to the entry/exit points in the storage channels to aid in the placement of the unit load in the channel, ensuring it has been centred.

Shuttle components

  • Wheels

    The shuttle runs smoothly along the inner lane thanks to these wheels and, as such, can move the goods.

  • Contrast wheel

    This type of wheels is used to guide the shuttle in the longitudinal direction.

  • Shuttle stops

    Used to prevent possible collisions or incidents resulting from improper use.

  • Aerial

    Receives orders transmitted via WiFi from the control tablet.

  • Safety bumper

    Used to prevent potential jams or collisions.

  • Safety scanner (optional)

    Installed on either side of the Pallet Shuttle to control access to the channels more safely while the shuttle is in operation.

  • Lifting platform

    The system lifts pallets via the platform, facilitating pallet movements.

  • Battery compartment

    Batteries are slotted into the shuttle and power the shuttle's movements.

  • Fault indicator

    This component warns if problems occur with the shuttle.

  • Battery status indicator

    Indicates the status of the batteries to know when it is necessary to recharge them.

  • On/off switch

    On/off indicator.

  • Emergency stop button

    Ensures the Pallet Shuttle stops for any preventive maintenance tasks.

  • End-of-track sensor

    Used to detect the position of the Pallet Shuttle at the ends of the channel.

  • Positioning camera (optional)

    Helps the operator to centre the shuttle between the two rails.

  • Pallet detector

    Used to detect the position of pallets that are loaded on the Pallet Shuttle, or that have been deposited.

  • Locking system

    Ensures the fastening of the shuttle on the lifting blades of the forklift, preventing it from moving during travel.



Load management systems

The semi-automated system allows for two types of operation:

  • LIFO (Last In, First Out)

    Where the last pallet loaded is the first to be unloaded. Loading and unloading is carried out from the same side. It is the most common system used with the Pallet Shuttle system.

  • FIFO (First In, First Out)

    Where the first pallet loaded is the first to be unloaded. Two access aisles are needed: One to load the goods and another to unload them. This FIFO system is relative, or by batches, recommended for completely loading or unloading a level.



Main features

The forklift operator sends the storage and retrieval orders to the shuttle through a WiFi tablet. Operation is very simple and intuitive, and does not require special training. The most noteworthy features are:

  • Pallet selector
    Pallet selector

    Selects the type of pallet to be handled.

  • LIFO/FIFO configuration
    LIFO/FIFO configuration

    Selects the load management strategy.

  • Change of P&D station
    Change of P&D station

    Selects which side of the structure you want to work on (in FIFO mode).

  • Locking system
    Locking system

    Activates the additional locking system, which increases contact between the Pallet Shuttle and the forklift forks.

  • Space-saving

    Groups pallets at the beginning (LIFO) or end (FIFO) of the channel.

  • Continuous loading/unloading
    Continuous loading/unloading

    Loads/unloads a channel without stopping.

  • Partial unloading
    Partial unloading

    Selects the number of pallets to be extracted.

  • Inventory

    Counts the number of pallets stored in the channel.

  • Location signal
    Location signal

    Activates the acoustic and light signals to identify the location of the selected shuttle.

  • User management
    User management

    Manages user permissions for the shuttles for authorized personnel.

  • Operating mode selector
    Operating mode selector

    Automatic or manual (for maintenance tasks).

  • Shuttle indicator
    Shuttle indicator

    Shows the number of shuttles in operation and their status.

  • Tiltmeter

    Detects the incorrect position of the shuttle within the channel.

  • Rescue

    Recovers the damaged shuttle from within the channel.

  • Position camera (optional)
    Position camera (optional)

    Facilitates the insertion of the Pallet Shuttle on the rails.



Automation accessible to everyone

In general, the Pallet Shuttle noticeably increases warehouse productivity when working with incoming and outgoing goods with a lot of pallets per item.

As such, it is the perfect option for:

  • Companies with few items and a large number of pallets..
  • Companies with a high level of loading and unloading activity.
  • Cold storage. It is ideal for warehouses where low temperatures are required, since it takes full advantage of the storage volume and reduces maneuvering times. The system is even more efficient when automated systems are installed, using stacker cranes or shuttles.
  • Buffers for temporary storage or picked orders.
  • Seasonal product warehouses, where inflow and outflow depend on the season, and goods are accumulated over a period until a given moment, when must all be released en masse, as is the case for ice creams or toys.
  • Warehouses that already use a compact system and need to access a greater number of items, store more pallets in depth or increase the number of incoming and outgoing movements, thereby increasing productivity.
Pallet Shuttle moving along the inside of a storage channel


Pallet Shuttle in motion to perform an unloading operation The WiFi control tablet has a very intuitive user interface The structure incorporates rail end stops to increase safety An operator handling a Pallet Shuttle with a reach truck Front view of the Pallet Shuttle The shuttle travels at 148 ft./min when loaded The batteries are easily accessible and have fast connections that eliminate the need for cables Storage channels reach up to 131 feet in depth The unloaded shuttle travels at 295 ft./min Optimization of loading and unloading operations The Pallet Shuttle is placed on the level where work is to be done A forklift places pallets one by one at the entrance to the level Pallet Shuttle slides the pallets horizontally to the nearest available space Once the pallet has been stored, it returns to the beginning of the channel to repeat the cycle Shuttle components with WiFi control The shuttle has numerous built-in safety features Fall-prevention device on the base of the shuttle The Pallet Shuttle system allows for references to be grouped by channel Different structural components specifically for the Pallet Shuttle system The contrast wheels guide the shuttle’s movements along the rails

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