Four-Way Shuttle Rack System – The Future of Fully Automated Warehousing
The Four-Way Shuttle Rack System by Vinatech Group is a next-generation, fully automated warehouse solution designed for large-scale, high-speed logistics operations. Using intelligent shuttle robots that move in four directions (forward, backward, left, and right), combined with conveyors, lifts, and WMS/WCS software, the system boosts storage density up to 90%, cuts labor costs by 70–80%, and increases throughput 5–7 times compared to traditional warehouses.
Ask For PriceWhat Is a Four-Way Shuttle Rack System?
The Four-Way Shuttle Rack System is an advanced automated storage and retrieval system (ASRS) that integrates:
- Four-way shuttle robots
- Conveyor networks and vertical lifts
- Specialized high-density racks
- Smart warehouse management software (WMS/WCS/WES)
Unlike the Two-Way Shuttle system, the four-way shuttles can travel in all directions, allowing unrestricted pallet access, flexible layout design, and seamless warehouse expansion without structural changes.
Each shuttle operates at speeds up to 1.5 m/s (unloaded) and 1.2 m/s (loaded), handling loads between 500–1,500 kg per pallet, running 24/7 with real-time system coordination through Siemens PLC and Vinatech’s intelligent control software.
System Architecture
1. Four-Way Shuttle Robots
- Load capacity: 500–1,500 kg per pallet
- Speed: 1.5 m/s (unloaded), 1.2 m/s (loaded)
- Power: 48V lithium battery, 7–8 hours continuous operation
- Temperature range: 5°C–45°C (custom versions for cold storage)
- Movement: Full 4-direction travel for optimal route efficiency
- Communication: Wireless link with WMS/WCS for instant coordination
2. Conveyor System
Handles pallet flow between storage, lifts, and outbound zones.
Includes automatic check stations for:
- Weight verification
- Dimension scanning
- Barcode/QR code reading
- Auto-reject for out-of-spec goods
3. Lift System
Vertical lifts transport shuttles and pallets between rack levels.
- Speed: 0.5–1 m/s
- Precision: ±2 mm
- 24/7 continuous operation with smart task scheduling
4. Warehouse Software Suite
- WMS (Warehouse Management System): Oversees inventory, storage positions, and order processing.
- WES (Warehouse Execution System): Coordinates real-time task distribution and load balancing.
- WCS (Warehouse Control System): Directly controls hardware—shuttles, conveyors, and lifts—for accurate execution.
Automated Workflow (6 Steps)
- Receiving: Pallets enter via forklifts, AGVs, or AMRs. The system automatically checks weight, dimensions, and barcode data.
- Lifting: The vertical lift moves pallets to designated rack levels.
- Shuttle Transfer: The four-way shuttle receives instructions from WCS and travels directly to the assigned storage location.
- Storage: The shuttle lifts, places, and records pallet data in WMS in real time.
- Retrieval: Upon order request, the shuttle retrieves the correct pallet and transfers it to the conveyor for dispatch.
- Auto-Charging: When the battery runs low, the shuttle autonomously returns to a charging dock without human intervention.
Core Advantages
1. Maximum Space Utilization
- 85–90% storage density, eliminating forklift aisles.
- Optimized for both horizontal and vertical expansion.
2. Superior Efficiency
- 5–7× faster throughput than manual operations.
- Intelligent AI routing minimizes travel distance and waiting time.
3. Fully Automated Operation
- Reduces labor costs by up to 80%.
- Continuous 24/7 unmanned operation with minimal downtime.
- Error rate <0.1% through automated inspection and barcode tracking.
4. Flexible & Scalable
- Add more shuttles as demand grows without layout changes.
- Supports multi-level, large-scale warehouses and cold storage environments.
5. Safety & Accuracy
- No forklifts or workers inside storage aisles → zero collision risk.
- Real-time inventory visibility and traceable pallet movement.
- Seamless integration with ERP/SAP and IoT systems.
Comparison with Other Systems
| Criteria | Four-Way Shuttle | Two-Way Shuttle | ASRS | Drive-in Rack |
| Storage Density | 85–90% | 80% | 90–95% | 70% |
| Throughput Speed | Very High | High | Very High | Low |
| Investment Cost | High | Medium | Very High | Low |
| Automation Level | Fully Auto | Semi-Auto | Fully Auto | Manual |
| Scalability | Excellent | Good | Average | Poor |
| ROI | 3–5 years | 2–4 years | 5–7 years | N/A |
| OPEX | Very Low | Low | Very Low | High |
Ideal Applications
- National distribution centers (e-commerce, FMCG, logistics hubs).
- Large-scale manufacturing (automotive, electronics, pharmaceuticals).
- Cold storage facilities (seafood, frozen food, cold logistics).
- 3PL/4PL providers requiring ultra-fast, high-accuracy operations.
- Digital transformation projects integrating WMS/ERP/IoT ecosystems.
Why Choose Vinatech Group?
✅ World-class technology: Components from Siemens, Schneider, and top automation partners.
✅ Proven expertise: 10+ years in smart warehousing, serving Vinamilk, Nestlé, Unilever, Maersk, DHL and others.
✅ Custom engineering: Tailored 3D simulations, ROI calculations, and optimized warehouse layouts.
✅ Full turnkey solutions: Design → Equipment → Software → Installation → Training → After-sales support.
✅ Long-term reliability: 24/7 technical service, preventive maintenance, and uptime >98%.
Vinatech Group – Vietnam’s Leading Warehouse Storage Solution Provider
Head Offices:
- Hanoi: 15th Floor, TTC Building, 19 Duy Tan, Cau Giay, Hanoi
- Da Nang: 219–223 Pham Hung, Hoa Xuan, Cam Le, Da Nang
- Ho Chi Minh City: Lot C2-7, N7 Street, Tan Phu Trung Industrial Park, Cu Chi District
