What Is Shuttle Racking?

Shuttle racking, sometimes referred to as a pallet shuttle system or radio shuttle, is a semi-automated pallet storage solution designed to make the most of every inch of your warehouse. Instead of forklifts entering deep into the racks, a motorised pallet shuttle carries pallets in and out of the lanes. The system is operated by remote control, and multiple shuttles can work simultaneously across different channels. At its core, shuttle racking is all about density and efficiency. Pallets are stored compactly, aisle space is minimised, and operators gain both speed and safety. If you’ve ever looked at your warehouse and thought, “Surely we can squeeze more out of this space” - shuttle racking is usually the answer!
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How It Works

Think of it this way: a forklift sets the pallet at the front of the lane, and from there the shuttle takes over.

It runs along the rails, lifts the load, and places it neatly inside the rack. When that pallet needs to come out, the shuttle brings it back to the front ready for collection.

Operators control the process with a simple handheld device, though in more advanced setups the shuttle links directly to a warehouse management system (WMS) for seamless operation.

The best part is that forklifts never need to drive into the racking itself. That saves time on every movement and helps prevent the bumps, scrapes, and wear that racks often suffer in busy warehouses.

If you are unsure on the system you require, we can discuss alternative options for your business, including:

The Benefits Of Shuttle Racking

Space Optimisation & High Storage Density

Space is expensive. Shuttle racking maximises usable capacity by cutting out wasted aisles and stacking pallets more tightly. It supports deep lane storage, making it ideal for operations that need to hold large quantities of the same SKU.

Improved Operational Efficiency

Because forklifts handle only the entry and exit points, loading and unloading become quicker. This improved flow can be the difference between meeting next-day delivery commitments and missing them.

Versatility

Shuttle racking is adaptable to various pallet sizes and weights, making it suitable for a wide range of industries, from food and beverage to automotive and pharmaceuticals.

Enhanced Safety and Compliance

Reducing forklift traffic inside racks means fewer risks of collision or structural damage. Safety sensors and automatic stops on the pallet shuttle further lower the chance of accidents. Learn more about racking safety standards.

Adaptability for Different Industries

From cold storage to retail distribution, shuttle systems can adapt to a wide range of industries. The design accommodates standard pallets, but modifications make it suitable for half pallets or even non-standard loads.

Energy Efficiency

With less forklift travel inside aisles, you save on fuel or battery usage. Over time, this translates into noticeable operational savings, not to mention reduced maintenance on trucks and racks.
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Is Shuttle Racking Right For Your Business?

Suitable Industries (e.g. Cold Stores, Seasonal Goods, Distribution Centres)

Cold stores, where aisle space must be kept to an absolute minimum, are prime candidates. Distribution centres handling seasonal peaks also benefit, as shuttle racking provides the flexibility to scale throughput up or down.

High-Turnover Products

Fast-moving consumer goods, beverages, or any line with rapid in-and-out demand are a natural fit. The pallet shuttle system keeps the flow consistent without bottlenecks.

Limited Aisle Access or Space-Constrained Warehousing

Where floor area is restricted, shuttle racking offers dense storage without compromising access. It’s especially effective as a deep lane storage solution in urban warehouses or facilities hemmed in by their surroundings.
Stamina Storage Systems offers full project management, and can help plan and design the perfect storage solution for your business.
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Key facts

  • Aisle width: N/A
  • Space utilisation: 85%
  • Pallet accessibility reduced
  • Low throughput speeds
  • Specialist forklift options

Technical Components & System Design

Shuttle Unit / Shuttle Cart

This is the heart of the system: a battery-powered pallet shuttle that moves pallets smoothly and securely.

Rails, Beams & Support Structures

Heavy-duty steel rails and beams provide the track along which the shuttle moves, ensuring durability and stability.

Safety Features

From obstacle detection sensors to emergency stop buttons, safety comes built in. The system pauses instantly if anything unexpected blocks the shuttle’s path.

Control Systems & Automation Interfaces

Operators typically use handheld devices, but shuttles can also link directly into automation platforms and WMS for full integration.
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Comparison With Other Storage Systems

vs Drive-In / Drive-Through Racking

Shuttle racking avoids the drawbacks of drive-in systems, namely high forklift traffic inside aisles. Damage risk and operator time are significantly reduced.

vs Live Storage / Pallet Flow

Unlike pallet flow, which relies on gravity and requires uniform pallets, pallet shuttle systems handle greater variability and don’t need steep gradients.

vs Conventional Selective Pallet Racking

Selective racking provides direct access to every pallet but at the cost of density. Shuttle racking strikes a balance, offering high density with managed access.

Why Choose Stamina Racking?

Support, Project Management & Service

From design consultation to installation, Stamina stays hands-on. Every project includes clear timelines, dedicated project management, and aftercare support.

Design & Planning with Stamina Storage

We model your warehouse layout to find the most effective configuration, ensuring you get density and efficiency without compromising safety.

Installation & Training

Our teams install, test, and train operators on the system. You’re not left figuring it out on your own.

Ongoing Maintenance & Safety Checks

Regular inspections, service checks, and replacement parts are all part of the service we can offer. Because a storage system is only as good as its upkeep.

UK Wide Service & Rapid Installation

Unlike global competitors who may offer generic packages, Stamina provides UK wide installation, fast turnaround times, and tailored project management. Our local expertise ensures your system is designed and delivered for the realities of the UK market, with responsive support when you need it most.
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Frequently Asked Questions

FIFO sends the oldest pallet out first, ideal for goods with expiry dates. LIFO takes the most recent pallet first, better for bulk or non-perishable stock. Shuttle lanes can be set up for either.

Small sites usually need one. High-volume warehouses often run two or more so multiple lanes can operate at once without delays.

Yes – standard units are built for UK or EUR pallets, but shuttles and rails can be customised for half pallets or non-standard loads.

Shuttles alert operators when the battery is low and return to the front automatically. Most sites keep a spare on charge to avoid downtime.

Shuttles can connect to your warehouse management system, so pallet movements and stock levels are tracked in real time.

Yes. Radio shuttle is just another name for a pallet shuttle system – both describe the same technology.

Typically up to 85% space utilisation, compared with around 65% for drive-in racks. That can mean up to 20% storage in the same footprint.