Dense Smart Warehouse: 4-Way Shuttle Racking System Delivers High-Density Flexible Storage for Packaging Industry

A large packaging manufacturer specializing in cartons for food and daily chemical products. It handles mass pallet turnover with abundant SKUs, requiring ultra-high storage density and flexible inbound & outbound capacity.

Project Background

Conventional pallet racking has low space utilization, stacked cartons easily get deformed by extrusion. Forklift aisles waste massive floor space. Fluctuating order batches and manual scheduling lead to low efficiency, failing to support capacity expansion.

Solution

Deploy 4-way shuttle high-density racking system, eliminating redundant forklift aisles and drastically expanding storage capacity
Multiple 4-way shuttles operate on shared tracks with lifts to realize automatic carton receiving, storage and batch shipping
WMS links with shuttles to auto-allocate locations, enforce FIFO rules and intelligently sort bulk orders

Project Difficulties

Paper cartons have weak compression resistance, requiring optimized shuttle load and rack support to prevent damage
Huge seasonal order gaps demand collaborative scheduling algorithms for both light and peak workloads
System integration with production MES and ERP to realize full-link data connection for raw materials and finished goods

Project Value

Space Gain: Storage density increased by 160%, doubling storage capacity within the same plant without expansion
Flexible Efficiency: Bulk handling throughput raised by 220%, carton damage rate cut by 70%, adapting to seasonal order fluctuation
Cost Optimization: Forklift usage sharply reduced, warehouse labor cut by 68%, saving 4.6 million RMB in annual operation costs