Pallet Shuttle System for Fast Turnaround Packaging Storage

A leading manufacturer of plasterboard and gypsum-based products required an improved storage solution for packaging materials, which were previously stored solely at floor level.

Operating a highly advanced site that spans from raw material extraction to production and distribution, the client needed a tailored storage system to support seamless operations. Teccon was selected to consult, specify, and install a comprehensive warehouse solution that would enhance production flow and logistics efficiency.

After a thorough design and consultation phase, the project was successfully delivered with a semi-automated pallet shuttle system and two distinct racking configurations for both palletised packaging and spools.

Challenge

High Volume, Fast Turnaround

The warehouse was solely dedicated to handling two packaging types, bags and spools, with rapid turnover.

Palletised bags were required in large quantities, demanding a high-throughput storage and retrieval system.

Any disruption in packaging availability could halt national product distribution, creating significant bottlenecks and logistical setbacks.

Solution

Maximised Storage Density

Leveraging the warehouse’s vertical space, we implemented a three-tier, 13-bay racking system with a depth of 10 pallets per bay, enabling storage of up to 390 pallets.

Compared to the original floor-level setup, this represented a fourfold increase in capacity.

To accommodate spool storage, a three-tier Dexion P90 racking system was installed, facilitating straightforward forklift access and organisation.

Semi-Automated Pallet Shuttle System

The Dexion semi-automated Pallet Shuttle System was deployed for efficient pallet handling.

Pallets are loaded onto the shuttle within each bay, which autonomously retrieves or stores them as required.

Planning and Roll-out

This turn-key solution was completed in 8 weeks, delivering the client a ready to go solution for consistent quality throughout.

Our proven systems, clear communication, and dedication to the client’s operational needs demonstrate why Teccon continues to inspire customer confidence and remains the first choice for storage solutions.