Pallet Shuttle Systems For Warehouse Automation

Jungheinrich and intralogistics specialist Automha have formed a strategic partnership to engineer and deploy two-way pallet shuttle systems for high-density storage within brownfield distribution facilities. The technical collaboration establishes a gradual modernization path that integrates mechanical storage units into existing logistics infrastructure without requiring civil structural adjustments.

Operational Challenges in Brownfield Facilities
Industrial operators often face floor space constraints and mounting throughput requirements, yet constructing new facilities or altering building structures is frequently unfeasible. Automating legacy sites requires solutions that accommodate pre-existing column grids, existing floor load capacities, and manual material handling fleets. The partnership addresses this complexity by combining Automha mechanical shuttle engineering with Jungheinrich capabilities in software connectivity, rack design, and lifecycle support.

Technical Architecture of the UP-Carrier GTJ
The core technical result of the cooperation is the UP-Carrier GTJ, a two-way pallet shuttle engineered for high-density channel storage. The shuttle operates within specialized deep-lane racking channels to automatically position, retrieve, and condense palletized loads.

In the initial implementation stage, external transport of pallets to the rack face is managed by standard manual industrial trucks. System control interfaces coordinate pallet placement, allowing the shuttle to manage internal channel movements independently. As operational volumes increase, the system architecture allows seamless integration with automated guided vehicles, autonomous mobile robots, and stationary conveying systems. This modular design permits facilities to upgrade from manual truck handling to fully automated intralogistics without altering the channel storage hardware.

Software integration links the shuttle controls directly with existing warehouse management systems. This maintains precise inventory visibility, cycle times, and operational diagnostics across all storage lanes.

Deployment and Performance Validation
The hardware and control architecture advanced from development to market readiness within nine months. The system operates across more than 200 projects in over 25 countries, validating its interoperability with diverse pallet dimensions and existing floor configurations.

"What matters is a development path that leverages existing infrastructure while opening the door to further automation," states Dr. Tobias Harzer, Chief Automation Officer at Jungheinrich. "With this solution, customers can start where they are today, gradually develop their material flows and align investments with the growth of their business."

Gianni Togni, VP Sales and Marketing of Automha, adds: "This partnership demonstrates how specialised shuttle technology and global integration expertise complement each other."

Target Applications and Industrial Scope
The system targets manufacturing warehouses, contract logistics hubs, and cold storage facilities requiring immediate density gains. By retrofitting existing facilities with channel shuttle technology, operations achieve higher volumetric efficiency, lower handling damage, and an integrated technical path toward autonomous material handling.

Edited by Sucithra Mani, Induportals editor – adapted by AI.

www.jungheinrich.com