Scalable Fulfillment
High-density pallet shuttle automation for 2-way and 4-way warehouse storage.
Overview
Metallum’s high-density pallet shuttle systems maximize warehouse space utilization and throughput across high-volume distribution hubs and manufacturing facilities. Operating autonomously within deep-lane racking channels, our 2-way longitudinal and 4-way multi-directional robotic shuttles transport unit loads with rapid acceleration and sub-millimeter positioning accuracy.
By replacing manual lift truck travel with automated channel navigation, vertical elevators, and mother-child vehicle configurations, our systems achieve up to 80% floor plan space utilization, enforce strict FIFO/LIFO inventory sequencing, and integrate seamlessly with high-bay AS/RS, AGV fleets, and robotic picking cells for continuous 24/7 lights-out fulfillment.
Types
Both options can be combined with vertical lifts, conveyors and AGVs in one system.
Longitudinal Deep-Lane Storage
Battery-powered shuttles travel along deep racking channels to deposit and retrieve pallets, fed at the rack face by forklifts, conveyors or AGVs. Ideal for high-volume, medium-SKU and cold storage.
500–1,500 kg · laden 0.8–1.2 m/s · 8–10 h LiFePO4 duty
Omnidirectional XY Travel
Travels along main cross-aisles and storage channels on any rack level, with vertical lifts transferring shuttles and pallets between tiers — no dedicated aisle cranes required.
500–1,500 kg · main track 1.2–1.6 m/s · reach up to 82 ft (25 m)
Features
Minimizes aisle space and maximizes storage channel depth for industry-leading high-density pallet storage.
More pallets per square foot in a smaller footprint.
Removes lift-truck maneuvering inside rack bays and consolidates access lanes.
Converts dead aisle space into storage capacity.
Autonomous robotic shuttles run on precision steel rails with high dynamic acceleration.
Faster order staging and truck loading cycles.
2-way deep-lane shuttles and 4-way multi-directional shuttles coordinate with vertical lifts and mother-child configurations.
Multi-level, multi-aisle flexibility without single-point bottlenecks.
Racking channels support First-In-First-Out or Last-In-First-Out rotation under real-time software control.
Strict batch and expiry management.
Process
Pallets are placed at rack entry points by forklifts, conveyors or AGVs; optical sensors verify alignment before the shuttle engages.
The shuttle lifts the pallet, drives autonomously into the channel and deposits it at the next optimized position.
On WCS command the shuttle retrieves the target pallet and returns it to the aisle front for pickup.
Compare
Key differences between deep-lane and multi-directional shuttles. Full parameters are listed under Specifications.
Specification2 models |  2-Way Pallet ShuttleLongitudinal Deep-Lane StorageGet a Quote |  4-Way Multi-Directional ShuttleOmnidirectional XY TravelGet a Quote |
|---|---|---|
| Movement | ||
| Travel | Longitudinal, along deep-lane storage channels | Omnidirectional XY — main cross-aisles and storage channels |
| Level changes | Fed at the rack face by forklifts, conveyors or AGVs | Vertical tier lifts; reach up to 82 ft (25 m) |
| Travel speed | Laden 157.5 – 236.2 ft/min (0.8 – 1.2 m/s) | Main track 236.2 – 315.0 ft/min (1.2 – 1.6 m/s) |
| Load & power | ||
| Rated load | 1,102 – 3,307 lb (500 – 1,500 kg) | 1,102 – 3,307 lb (500 – 1,500 kg) |
| Pallets | GMA (48 × 40 in) and Euro (1200 × 800 mm) | GMA (48 × 40 in) and Euro (1200 × 800 mm) |
| Power supply | 24V / 48V LiFePO4; 8–10 h duty; 2–3 h recharge | 48V high-rate LiFePO4; automated inline charging (<30 min) |
| Positioning | Dual closed-loop optical encoders | Laser ranging + 2D matrix optical code |
| Best for | High-volume, medium-SKU and cold storage | Multi-level, multi-aisle storage without dedicated aisle cranes |
IncludedNot applicable or confirmed per project
Specifications
2-way pallet shuttle versus 4-way multi-directional shuttle.
| Specification | 2-Way Pallet Shuttle | 4-Way Multi-Directional Shuttle |
|---|---|---|
| Rated load capacity | 1,102.3 – 3,306.9 lb (500 – 1,500 kg) | 1,102.3 – 3,306.9 lb (500 – 1,500 kg) |
| Travel velocity | Laden: 157.5 – 236.2 ft/min (0.8 – 1.2 m/s) Unladen: 275.6 – 354.3 ft/min (1.4 – 1.8 m/s) | Main track: 236.2 – 315.0 ft/min (1.2 – 1.6 m/s) Storage channel: 177.2 – 236.2 ft/min (0.9 – 1.2 m/s) |
| Acceleration | 1.64 – 2.62 ft/s² (0.5 – 0.8 m/s²) | 1.97 – 3.28 ft/s² |
| Lifting | Lift stroke: 0.87 – 1.57 in (22 – 40 mm) Lift cycle: 1.5 – 2.5 s | Tier lift hoist: 78.7 – 196.8 ft/min (0.4 – 1.0 m/s) Vertical reach: up to 82.0 ft (25 m) |
| Power supply | 24V / 48V LiFePO4; 8–10 h continuous duty; 2–3 h recharge | 48V high-rate LiFePO4; automated inline charging (<30 min) |
| Drive & positioning | 4-wheel polyurethane direct drive; brushless DC servomotor; dual closed-loop optical encoders | Dual-drive 8-wheel switching chassis; laser ranging + 2D matrix optical code positioning |
| Operating environment | Ambient 32°F to 104°F; cold storage -22°F to 32°F | Wi-Fi 6 / 5G industrial roaming; LiDAR anti-collision |
| Lane depth | Deep-lane channels up to 30+ pallets deep | Any rack level, across cross-aisles and storage channels |
Supports standard GMA (48 × 40 in) and Euro (1200 × 800 mm) pallets.
Applications
Large volumes of standardized goods with moderate SKU counts in consolidated deep lanes.
Dynamic buffer between end-of-line production and outbound dispatch.
Low-temperature components and battery management for -20°F to -40°F environments.
Sequenced pallet retrieval synchronized with picking stations and delivery routes.
Integration
Shuttles form the ultra-dense storage core of integrated automated warehouses.
Deep-lane shuttle racks integrated into multi-tier clad-rack or high-bay structures, interfaced via vertical hoists or crane spurs.
Carton shuttles and pallet shuttles coordinated under a unified WCS — bulk reserve and carton-level picking in one footprint.
Pallet lift handoffs feed robotic depalletizing cells and goods-to-person picking based on live order demand.
Chain and roller transfer decks bridge robotic palletizers directly into shuttle entry lanes.
Heavy-duty AGVs transport pallets between receiving docks, shuttle elevator ports and dispatch lanes.
Bidirectional WCS handshake synchronizes high-bay stacker cranes with tier-level shuttle channels.
Shuttle Systems
Share your facility layout, load profile and throughput targets — we will recommend the right configuration.
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