In today’s fast-paced logistics landscape, warehouse efficiency is crucial. The surge in e- commerce has fundamentally changed how businesses approach storage solutions.
Moreover, choosing the right storage racking system can make or break your operational efficiency. This guide dives deep into two leading contenders: Automated Shuttle/Satellite, and Manual/Integrated System.
Are you struggling to decide which system best suits your warehouse needs? You’re not alone. Hence, we’ve created this in depth comparison to help you make an informed decision that aligns with your specific requirements.
Understanding the Systems: How They Work
Before we compare these systems head-to-head, let’s clarify exactly how each one functions. Understanding these mechanics is crucial for making the right investment.
Shuttle Racking System [Full Automation]:
A shuttle racking system that is fully automated employs a motorized pallet shuttle that moves independently within deep lane racking. This device transports pallets without requiring forklift intervention throughout the entire process.
How it Works:
- Forklift operators place the shuttle into the designated racking lane
- The shuttle, controlled remotely, moves pallets within the rack
- Operators retrieve the shuttle after it completes its task
Key Benefits:
- High storage density
- Reduces forklift movement, increasing safety
- Can operate in cold storage environments
Shuttle Racking System [Semi – Automation]
The satellite racking system is a semi-automated storage solution that utilizes a satellite device to move pallets in and out of deep lane racking. This racking system strikes a balance between automation and manual operation.
How it Works:
- A remote-controlled satellite device handles pallet movement within lanes
- Forklift operators place and retrieve pallets at the lane entrance
- The satellite can be moved between different lanes as needed
Key Benefits:
- Maximizes warehouse space
- Reduces aisle requirements
- Allows forklift operators to focus on other tasks
Manual Integrated Systems [Pushback]
The pushback pallet racking system is a Last-In, First-Out (LIFO) solution that uses inclined rails and moveable carts to store pallets in deep lanes. It’s offers significant space optimization for a warehouse racking setup.
How it Works:
- Each new pallet physically pushes previous pallets deeper into the lane with the aid of the moveable push cart.
- When unloading, gravity automatically allows pallets to flow forward to the picking position
- The system requires no electrical components or sophisticated controls
Key Benefits:
- Cost-effective high-density storage with usage of heavy duty rack
- Ideal for non-perishable goods
- Simple to maintain with no electrical components for this type of pallet racking system
Manual Integrated Systems [SCPL 1 & 2]
The Serrated Chain Pallet Link System/Spring Chain Pallet Link System [SCPL] is a high density storage and retrieval system which utilizes chain hooks and spring chain as mentioned in its name. Easily operated by conventional forklift and can also be installed on your existing pallet racking to increase the pallet capacity. Furthermore, it provides user friendly accessories such as a yellow tag lane indicator.
How it works:
- Pallet is loaded onto the rails. Each new pallet loaded pushes the previous pallets deeper with the usage of rollers until the lane is filled up.
- The indication of the filled lane is seen when the yellow tag is not visible anymore as the tag moves together when the last pallet enters
- This approach is similar for both systems.
Key Benefits:
- System doesn’t require any electrical components
- Increases up to 40% pallet storage as compared to normal APR and double deep racking
- Able to be installed on existing pallet racking without spending extra cost on new racks
Key Metrics: A Head-to-Head Comparison
When evaluating these systems, several critical factors come into play. The table below provides a quick reference for comparing the three types of warehouse racking systems of three different types across essential metrics:
| Metric | Shuttle & Satellite Racking | Pushback Racking | SCPL 1 & 2 |
| Space Utilization | High – maximizes depth & minimizes aisles | Moderate – good but limited to LIFO | Moderate – good but limited to LIFO |
| Throughput | High – Automated movement speeds operations | Moderate – depends on forklift speed | Moderate – depends on forklift speed |
| Investment | High Upfront Cost
High Upkeep Cost |
Low Upfront cost
Moderate Upkeep Cost
|
Low Upfront cost
Moderate Upkeep Cost |
| Long-term ROI | Excellent for high-volume operations | Best for medium operations | Best for medium operations |
| Inventory Management | Supports both FIFO & LIFO | LIFO only | LIFO only |
| Safety Rating | Excellent – reduces forklift traffic | Good – relies on forklift operation | Good – relies on forklift operation |
| Maintenance Requirements | Regular maintenance of shuttles needed | Minimal maintenance needed | Minimal maintenance needed |
| Cold Storage Compatibility | Excellent | Limited | Limited |
When to Choose Each System
Selecting the right warehouse racking system depends heavily on your specific operational needs. Let’s explore when each system shines brightest.
Ideal Use Cases for Shuttle Racking
Pallet shuttle systems excel in high-volume environments where maximum efficiency and an excellent balance. They’re particularly well-suited for:
- Medium / large distribution centers handling thousands of pallets daily
- Operations requiring both FIFO and LIFO storage flexibility
- Cold storage facilities where minimizing door openings is crucial
- Warehouses with labor shortage challenges
- Warehouses handling multiple product lines with medium turnover rates
Ideal Use Cases for Pushback Racking
Pushback pallet racking systems offer an affordable entry point to high-density storage and are ideal for:
- Smaller businesses or warehouses with budget constraints
- Industries handling non-perishable goods where LIFO storage is acceptable
- Warehouses with a high volume of a few SKUs
- Operations seeking simplicity and minimal maintenance with a heavy duty rack
The Automation Factor: Semi vs Fully Automated
The level of automation on a racking system significantly impacts both cost and operational efficiency. Let’s examine the options:
Making Your Decision: A Practical Framework
When evaluating these systems for your operation, consider this step-by-step approach:
1. Assess your inventory characteristics:
- Volume and turnover rates
- Product dimensions and weight
- FIFO vs LIFO requirements
2. Evaluate your operational constraints:
- Available budget
- Space limitations
- Labour availability
- Temperature requirements
3. Project future needs:
- Anticipated growth
- Seasonal fluctuations
- Changing product mix
4. Calculate total cost of ownership:
- Initial investment
- Installation disruption
- Ongoing maintenance
- Energy requirements
- Labour savings
5. Request demonstrations and site visits:
- See similar operations in action
- Speak with current users
- Test with your specific product types
Conclusion
The right automated racking system can transform your warehouse operations, boosting efficiency, reducing costs, and improving safety.
Shuttle systems offer the highest level of automation and efficiency but come with significant investment. Meanwhile, satellite systems provide an excellent middle ground with good density and moderate automation.
Pushback pallet racking system, on the other hand, deliver improved density at the lowest cost point, though with some operational limitations.
By carefully evaluating the factors outlined in this guide, you can benefit in terms of space optimisation, improved budget, throughput, and effective inventory management in your unique warehouse environment.
Ready to optimise your warehouse racking system?
Storage Centre offers industry-leading pallet racking systems tailored to your specific needs.
Our team of storage experts will guide you through the entire process, from initial consultation and custom design to professional installation and ongoing customer support
Take the next step towards warehouse optimisation today. Visit our Storage Centre website or contact us at +65 6863 3688 to book your no-obligation consultation on our complete range of warehouse racking solutions.
