Shuttle Pallet Racking System – The Ultimate High-Density Storage Solution by Bari Engineering
In today’s fast-paced warehousing environment, speed, accuracy, and efficient space utilization are more important than ever. To overcome the challenges of limited floor space and high-volume inventory movement, Bari Engineering brings you an advanced, semi-automated storage innovation — the Shuttle Pallet Racking System.Designed for warehouses that demand high-density storage, reduced forklift travel, and maximum throughput, shuttle racking is transforming storage operations across Pakistan.
What Is a Shuttle Pallet Rack?
A shuttle pallet rack, (also referred to as a pallet shuttle or shuttle racking system), semi-automated, high-density storage system uses a battery-operated shuttling vehicle that is actuated either by the manual operation of a worker or an automated process to move pallets within deep lane storage locations. Instead of unloading/loading pallets in to or out of the racking structure using a forklift, the shuttle vehicles transport pallets inside the racking system, which provides several operational benefits:
increased operational speed
improved safety
better use of storage space
elimination of labor costs
The use of the shuttle vehicle will generally only require the use of a forklift to load the pallets in to the space or unload the pallets from the storage racks.
How Shuttle Pallet Racking Works
The forklift places the pallet at the lane entrance.
The shuttle cart, operated via a wireless remote, carries the pallet deep into the lane.
For retrieval, the shuttle brings pallets back to the aisle.
The system supports both FIFO and LIFO inventory methods.
This makes shuttle racking one of the smartest systems for high-throughput warehouses.
Types of Shuttle Pallet Racking Systems
Bari Engineering manufactures several configurations depending on warehouse flow and SKU movement:
1. LIFO Shuttle Racking (Single Aisle – Deep Lane)
Last In, First Out
Ideal for bulk storage with low SKU variety
Offers maximum storage density
2. Double-Deep LIFO Shuttle Racking
Two racking blocks back-to-back
High-density storage with better SKU management
3. FIFO Shuttle Racking (Dual Aisle System)
First In, First Out
Perfect for food, beverages, pharmaceuticals, and other expiry-based products
4. Hybrid Picking + Shuttle System
Shuttle storage at upper levels
Conventional/live racking at lower levels
Ideal for fast order fulfillment
Benefits of Shuttle Pallet Racking
1. Maximum Storage Capacity
Deep lane storage up to 40–60 meters, reducing aisles and maximizing cubic space.
2. Faster Warehouse Throughput
The shuttle performs pallet handling inside the rack, boosting loading/unloading speed significantly.
3. Improved Warehouse Safety
Less forklift travel inside racks → fewer accidents, less structural damage.
4. Supports FIFO and LIFO
Flexible for different industries, product rotations, and storage strategies.
5. Lower Operational Costs
Reduced labor
Less forklift usage
Energy-efficient system (perfect for cold storage)
6. High Automation Capability
Shuttles work with wireless remotes or semi-automated controls — minimal operator training required.
Where Shuttle Pallet Racking Is Used
Shuttle racking is ideal for:
Cold Storage & Freezers
Food & Beverage Warehouses
Pharmaceutical Storage
Distribution Centers
High-Volume SKUs
Manufacturing Plants
Fast-Moving Consumer Goods (FMCG)
Bari Engineering designs these systems to operate efficiently even in harsh temperature-controlled environments.
Conclusion
The Shuttle Pallet Racking System by Bari Engineering defines the future of high-density storage. With semi-automated shuttle car capabilities, deep-lane storage, and excellent warehouse efficiency, it’s a solution for any business seeking improved speed, safety, and space utilization.If you want your warehouse to function more intelligently with enhanced speed, efficiency, and productivity, then shuttle racking is your upgrade.
