May 2024
Pallet Shuttle
Pallet shuttles are automated carts that move along tracks inside storage lanes. They can retrieve or place pallets deep within a rack structure, making them ideal for high-density storage. These systems reduce the need for forklifts to enter the aisles, thereby enhancing safety and reducing operational times.
In contrast to AS/RS, pallet shuttle systems require less complex machinery and are mainly focused on increasing storage density rather than automating every aspect of the storage process. They still rely on forklift operators to position the shuttle at the start of a lane but offer faster loading and unloading times and better space utilization than traditional racking systems.
What About Pallet Selection
As Dr. White has emphasized for years, automation and unit load packaging should be considered collectively during system design rather than having pallets as an afterthought. Initial savings on automation can prove to be false economy if the system operator must continue to use specialized pallets over the life of the system to ensure uptime.
By design adjustments such as reducing pallet spans in material handling equipment such as racking, conveyor rollers and other beam supports, users can utilize more inexpensive pallets than they otherwise would and reduce overall spend.
Automation Vendors Talk Pallets
“The main thing to keep in mind with all automated systems is that automation LOVES consistency,” Alex Reed, sales director, integrated solutions, Swisslog Americas shared in an email. “Swisslog is able to accommodate a variety of pallet types in a consumer products system, with the most common being GMA, CHEP, and PECO. From a sizing standpoint, these pallets are normally 40x48 inches or 48x48 inches in the US.
“When working with a customer, we set acceptable parameters for these systems, such as the pallets being grade A (if possible) with their bottom boards and stringers intact. Recycled pallets can work in these systems if they meet the requirements and tolerances we lay out in our proposals. We also make sure that pallets are inspected before entering an automated system. If pallet quality is a concern, we consider captive system pallets or support boards as possible options.
“Swisslog can design automated systems to handle many different loads for a variety of industries. These can include carts, reels, metal cages, and pallet sizes and materials—plastic, metal, etc.”
For Kyle Nevenhoven, Head of Solution Consulting Americas at Dematic, the most common types of pallets that that company deals with are GMA pallets, CHEP pallets, and PECO pallets. “When GMA pallets are used,” he said, “they are often placed on system pallets or system boards to increase reliability while handling pallets of varying quality.”
“Recycled pallets—those made of recycled materials—are just starting to appear in customer applications. The ability to handle these without system pallets or system boards is still somewhat of an unknown.”
When Pallets Pose Problems
“Automation systems work best when pallets are consistent and of high quality,” Nevenhoven stated. “The most common fault
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seen in pallet automation is broken bottom (Cont'd on P boards on a pallet. Broken bottom boards can create faults in many different areas of automation, such as preventing the ability to convey a pallet or impeding a pallet from being stored and retrieved safely and reliably.”
Reed echoed the importance of consistent quality. “Automated systems love consistency,” he commented. “Pallet and load quality issues are the top reasons for faults within automated systems, which can create issues both during commissioning and once a system is fully up and running. Broken top and bottom boards, along with pallet deflection, cause the most faults, as the automated systems are either unable to convey the pallet or retrieve it once it is in storage.”
Excessive pallet deflection can also disrupt operations in systems. Nevenhoven noted: “As many pallet storage systems support pallets on two rails, the deflection of a pallet in storage is an important consideration; pallets that deflect too significantly are often unusable in automation as the deflection may cause interference with the load handling device used by the storage system.”
Warehouse Automation
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