Shuttle Systems & Pallet Shuttle Storage

What Is a Pallet Shuttle System?

A pallet shuttle system (also called a pallet runner, radio shuttle, or pallet mole) is a semi-automated storage and retrieval solution for warehouses that require deep-lane, high-density storage. Pallet shuttle carts travel on rails within a racking system, moving pallets between the pick face and deep storage locations with the push of a button—eliminating the need for forklifts to enter the rack.

• Maximum Storage Density: Store up to 100+ pallet positions deep in a single lane for ultimate warehouse space efficiency.
• Fast & Safe: Reduce forklift travel, increase throughput, and minimize product and rack damage.
• Flexible Inventory: Supports both FIFO (first-in, first-out) and LIFO (last-in, first-out) inventory management.
• Semi-Automated: Remotely controlled shuttle carts handle movement; forklifts only interact at the rack face.
• Labor Savings: One operator can control multiple pallet runners—lowering labor needs and boosting productivity.
• Deep Lane Solution: Ideal for food, beverage, cold storage, and any operation that stores large volumes of the same SKU.

How Does a Shuttle System Work?

Shuttle systems use battery-powered, self-propelled carts that travel beneath pallets on rails within the rack. A forklift places the shuttle cart into a storage lane, and the operator uses a wireless remote to direct the cart to move pallets in or out. Pallet runners retrieve, deliver, or reposition pallets—optimizing workflow and reducing forklift traffic inside the system. Many shuttle systems are Wi-Fi enabled and can be programmed for daily cycles.

Shuttle System vs. Pallet Flow Racking

While pallet flow racking is effective for deep-lane, FIFO storage, shuttle systems offer even greater lane depth—up to 100+ pallets per lane. Shuttle systems can be designed for both FIFO and LIFO operation and support multiple SKUs by channel, while reducing aisle requirements and forklift travel.

Shuttle System Maintenance & Operation

Shuttle systems are reliable and designed for long-term performance. Daily charging of battery-operated carts is standard, and operators receive full training on best practices for loading, unloading, and maintenance. Backup carts ensure no operational downtime, and routine maintenance keeps your system running at peak efficiency.

Is a Shuttle System Right for Your Warehouse?

• Perfect for operations needing very deep lane storage (40, 60, 100+ pallets deep)
• Best for high-volume, low-SKU or batch storage environments
• Reduces labor, product damage, and rack maintenance
• Works in a range of industries: food, beverage, cold storage, manufacturing, e-commerce, and more
• Custom engineered for each facility and pallet specification

Pallet Shuttle System Cost

Pallet shuttle systems generally range from $1,200 to $2,000 per pallet position, depending on lane depth, system configuration, and custom requirements. While more affordable than fully automated AS/RS, shuttle systems offer a quick ROI through reduced labor, improved efficiency, and higher storage density.