Pallet Shuttle Systems
Pallet Shuttle Systems
Semi-automated deep-lane storage that goes where push back and drive-in can't. A motorized shuttle handles pallet movement inside the channel so forklifts never enter the rack.
30+
Pallets Deep
3,300 lbs
Shuttle load capacity
FIFO or LIFO
Configurable flow direction
A pallet shuttle system is a semi-automated compact storage solution that uses a motorized shuttle to move pallets inside deep storage channels. The shuttle travels along rails and is controlled via a Wi-Fi tablet, eliminating the need for forklifts to enter the rack structure. Channels can exceed 130 feet in depth, and the system supports both FIFO and LIFO inventory flow.
The Right Application
When You Need More Depth Than Manual Systems Can Deliver
Deep-Lane Bulk Storage
Push back tops out at 6 pallets deep. Drive-in requires forklifts inside the lane and still has practical depth limits. The Pallet Shuttle handles channels over 130 feet deep without a forklift ever entering the structure, making it the right answer when you need serious density.
High-Throughput Cold and Freezer Operations
The shuttle is rated from -22°F to 113°F and runs on lithium batteries with up to 10 hours of continuous operation. In conditioned space where every minute of forklift exposure costs energy, the shuttle minimizes time spent in the lane and keeps doors closed longer.
High-Volume SKU Consolidation
Items are grouped by channel instead of by entire lane, which means more SKUs can be stored in a high-density footprint. A single shuttle can serve multiple channels, and up to 18 shuttles can be controlled from one tablet.
Technical Specifications
Key Specs & Configuration
| Channel Depth | Storage channels can exceed 130 ft in depth |
| Shuttle Capacity | Up to 3,300 lbs per pallet |
| Speed (Unloaded) | 295 ft/min |
| Speed (Loaded) | 148 ft/min |
| Lift Cycle | 2 seconds |
| Operating Temperature | -22°F to 113°F (freezer to ambient) |
| Battery | Lithium, up to 10 hours at full capacity; quick cable-free swap |
| Control | Wi-Fi tablet, up to 18 shuttles per device |
| Pallet Sizes | Accommodates 32", 40", and 48" pallets |
| Inventory Method | FIFO or LIFO, configurable per channel |
| WMS Compatible | Interlake Mecalux Easy WMS integration available |
Brands We Carry
Built With Industry-Leading Components
How It Works
How the Pallet Shuttle Works
The system uses a motorized shuttle that rides on rails inside each storage channel. A forklift places the shuttle in the channel where work needs to be done. The operator then positions pallets one by one at the channel entry point, resting them on load-bearing beams. The forklift never enters the rack.
The shuttle lifts each pallet slightly, moves it horizontally to the deepest available position, deposits it, and returns to the channel entrance for the next pallet. This cycle repeats until the channel is full. When unloading, the shuttle performs the same operation in reverse, bringing pallets back to the aisle face for forklift retrieval.
The system is configurable for FIFO or LIFO inventory flow. In LIFO mode, loading and unloading happen from the same aisle face. In FIFO mode, pallets are loaded from one side and retrieved from the other. The shuttle is controlled via a Wi-Fi tablet with an intuitive interface that manages pallet selection, flow direction, continuous loading, partial unloads, and channel inventory counts.
What You Get
Built In, Not Bolted On
Motorized Shuttle Operation
A battery-powered shuttle handles all in-lane pallet movement at up to 295 ft/min. Forklifts work only at the aisle face, which eliminates column damage risk and simplifies traffic patterns.
Freezer-Rated to -22°F
Lithium batteries and the shuttle mechanism operate at sub-zero temperatures with 10 hours of continuous runtime. Quick cable-free battery swaps keep workflow uninterrupted.
Engineered and Permitted
Full structural engineering, stamped drawings, and permit coordination. Seismic compliance built into the design, not retrofitted.
Best Suited For
Common Applications and Industries
Cold & Freezer Storage
Rated to -22°F with 10-hour lithium battery life. Reduces forklift exposure in conditioned space and protects product integrity.
Food & Beverage
Deep channel storage for high-volume date-sensitive SKUs with FIFO or LIFO flexibility per channel.
Third-Party Logistics
Channel-based SKU segregation supports multi-client zoning with density far beyond manual racking systems.
Warehouse Distribution
High-throughput bulk storage with shuttle speeds up to 295 ft/min unloaded. Buffer inventory and preload trailers ahead of schedule.
Related Services
We Handle Design, Installation & Permitting
Other Systems to Consider
Related Storage Systems
Drive-In Racks
Manual deep-lane LIFO storage. Lower cost than shuttle systems but requires forklifts to enter the lane.
Learn More →
Push Back Racking
Gravity-assisted LIFO storage up to 6 pallets deep. No forklift lane entry, but limited depth compared to shuttle.
Learn More →
Automated Storage
Fully automated AS/RS for operations that need hands-off pallet handling from storage through retrieval.
Learn More →FAQ
Common Questions
How does the Pallet Shuttle compare to drive-in racking?
Drive-in racking requires forklifts to physically enter the lane to place and retrieve pallets, which increases column damage risk and limits practical depth to around 10 pallets. The Pallet Shuttle eliminates forklift lane entry entirely. A motorized shuttle handles all in-lane movement, so channels can exceed 130 feet in depth. The shuttle also supports both FIFO and LIFO flow, while drive-in is LIFO only. Throughput is significantly higher because the shuttle moves at up to 295 ft/min versus manual forklift cycle times inside the lane.
Can the shuttle operate in freezer environments?
Yes. The Interlake Mecalux Pallet Shuttle is rated for operating temperatures from -22°F to 113°F. The lithium batteries provide up to 10 hours of continuous operation at full capacity, even in sub-zero conditions. Quick cable-free battery changes keep operations running without downtime. This makes the system a strong fit for cold storage and freezer warehouses where minimizing forklift time in conditioned space is critical.
How many shuttles do I need per system?
The number of shuttles depends on your throughput requirements and how many channels are active simultaneously. A single shuttle can serve multiple channels since the forklift moves it between channels as needed. Up to 18 shuttles can be controlled from a single Wi-Fi tablet. For most operations, we right-size the shuttle count during the design phase based on your inbound/outbound volume and the number of active channels at peak demand.
Ready to Go Deeper Without Going Manual?
We'll evaluate your storage depth, throughput needs, and temperature requirements to determine if the Pallet Shuttle is the right fit. Free consultation, no obligation.
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