Decision support: Pallet Flow or Pallet Shuttle System? © Fraunhofer Institute for Material Flow and Logistics

The rack construction, the shuttle vehicles and the guide rails under each rack channel are the main components of the Pallet Shuttle System. The built-in sensors and mechanical safety devices ensure precise positioning and process reliability. This racking system is usually used for Euro pallets. The selection of pallets in this racking system is restricted by the design of the shuttle. The shuttle also influences the conveying direction of the pallets. When transporting the pallets in a transverse direction, the load carrier must be picked up from the side during storage and retrieval.

Advantages and possible combinations of the systems

Both technologies have different strengths and weaknesses, so the recommendation for a system depends very much on the scenario in question. Pallet flow systems are the preferred choice in most cases in terms of technology and processes. They are characterized in particular by high performance, simple integration into the overall system and lean processes. These advantages are reflected in lower operating costs. The system is particularly suitable for companies with high throughputs and material flows with continuous longitudinal alignment of the pallets. Typically, channel lengths of up to around 14 pallet spaces are a suitable dimensioning framework.

Pallet shuttle systems: good for large storage dimensions

Pallet Shuttle systems are characterized by low initial investment and are the preferred choice for very large storage dimensions. The system is particularly suitable for storage areas with lower throughput requirements and long channel lengths. The shuttle systems are also used when goods need to be stored for longer periods and with particular care. The system is particularly suitable for companies that want to store a large number of pallets of the same product type with a comparatively low investment and where the transverse alignment of the pallets is not a disadvantage for the material flow.

Use case decides

Both systems are a robust and durable solution for high-density pallet storage, provided they are properly maintained, clean and of the appropriate pallet quality. They also offer significant opportunities when integrated with automation technologies. The two technologies do not have to be mutually exclusive.

The strengths of both technologies can also be combined in a hybrid design. The lower level could be designed as a pallet flow system and the levels above as a pallet shuttle system. In this way, partial quantities could be handled at peak times with high throughput and lean processes on the lower level, while the upper levels can be used for pallets with a lower turnover rate at lower investment costs. The full study can be obtained free of charge from the website of the Fraunhofer Institute for Material Flow and Logistics.

Interview with Managing Director Mr. Stephan Holdenried from Euroroll

Euroroll was one of the initiators of this study by Fraunhofer IML. What was your own contribution to the work on the study?

Holdenried: We worked with Fraunhofer IML to incorporate our many years of expertise in the development and sale of gravity pallet solutions into the study. Their aim was to understand our experience as well as the standards and applications on the market. Among other things, we provided information on which industries are typical target groups and in which environments our solutions are used. In addition, IML wanted us to find out what challenges our customers might face when using the systems, what functions the solution offers and what potential problems might arise in comparison to the shuttle solutions.

The main aim of this study was to provide guidance on which applications Pallet Flow and when Pallet Shuttle is the more suitable system. Were there any surprising findings for you? What do you take away with you?

IML wanted to publish an independent white paper that compares both systems in detail and highlights the so-called "sweet spots" of both solutions. Specific applications, environments and industries were taken into account for which one or the other system offers the more suitable solution.

The results of the study are no surprise to us; there is a specific goal for each technology, and depending on the requirements of different projects and applications, one solution is more suitable than the other. For Euroroll, the key point is that both pallet flow and shuttle systems offer increased efficiency for high-density storage solutions. The white paper will help the reader decide which storage solution best suits their needs and requirements. And in many cases, whether it's high throughput or high storage capacity, the pallet flow system could potentially be the right solution.

Will the results of the study also be reflected in Euroroll's solutions in the medium and long term? Are there already ideas that you can talk about today?

As the study takes into account many factors such as space requirements, process integration, sustainability, investment and operating costs, external influences, automation potential and throughput capacity; it will help Euroroll to focus on the development of specific solutions and applications. These will help our customers to meet their future storage needs with durable solutions that can also be fully integrated with automation technologies. The aim is to support decision-makers in intralogistics by comparing the two systems, for which factors such as throughput requirements, operational strategies, product-specific requirements and budget considerations are of course crucial.