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PROJECTSAfter Haigelis entered the international market in 2011, it exported supermarket equipment, warehousing equipment, and related supporting products to countries and regions such as North America, South America, Europe, Southeast Asia, and Africa. In recent years, the company has increased its efforts in the research and development of automated warehousing equipment.
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Boost Warehouse Efficiency with HEGERLS Two‑Way Pallet Shuttle
Classification:
Enterprise News
Release time:
2025-11-24
In an era where e‑commerce, rapid fulfilment and space constraints converge, warehouse operators are under immense pressure to maximize storage density while reducing handling time, labour cost and energy usage. The warehouse automation market in 2025 is estimated at USD 29.91 billion, and is projected to reach USD 63.36 billion by 2030 — a robust Compound Annual Growth Rate (CAGR) of approximately 16.2%.
At the same time, the need for high‑density automated solutions is being driven by labor shortages, rising wages and stricter fulfillment requirements.
Against this backdrop, HEGERLS introduces its Two‑Way Pallet Shuttle System — a turnkey, scalable solution designed to deliver high‑density storage, rapid throughput and low total cost of ownership (TCO) for modern warehouses.
What is a Two‑Way Pallet Shuttle System?
A two‑way pallet shuttle system is an automated storage and retrieval solution (AS/RS) engineered to move pallets bidirectionally into racking lanes — horizontally and vertically — using a shuttle vehicle that travels on rails within the racking. Unlike traditional crane‑based AS/RS, the shuttle system optimizes aisle space, increases storage capacity and significantly boosts pick/put‑away speed.
Key Features of HEGERLS Two‑Way Pallet Shuttle
High Load Capacity & Precision: Each shuttle supports up to 1700 kg (or as configured) and operates with repeatability within ±3 mm, ensuring safe, accurate pallet placement and retrieval.
Bidirectional Movement: The shuttle travels both laterally and longitudinally, enabling flexible access to pallets without the need for a crane to traverse the entire lane.
Seamless Software Integration: Fully compatible with Warehouse Management Systems (WMS) and Warehouse Control Systems (WCS) — HEGERLS offers customized control modules to ensure real‑time tracking and intelligent operation.
Scalable Architecture: Modular by design, the system adapts to small‑to‑large‐scale warehouse deployments and supports future expansion.
Energy‑Efficient Operation: Compact motors and optimized travel paths reduce power consumption and thus operating cost.
Safety & Reliability: Advanced sensors, anti‐collision algorithms and fail‑safe mechanisms guarantee safe operations, even in multi‑shift, high‑density environments.
Why Choose HEGERLS Two‑Way Pallet Shuttle for Your Warehouse?
Supercharge Warehouse Throughput — 3–5× Faster Than Manual Handling
Traditional forklift operations involve constant waiting, travel time, and human error.
HEGERLS Two-Way Shuttle eliminates these issues with automated cargo handling, continuous operation, and intelligent routing.
High-Speed Storage and Retrieval
- Travel speed up to 1–2 m/s
- One storage action completed in 10–20 seconds
- Handles 30–50 pallets per hour
That’s 3–5× the efficiency of a traditional forklift-based workflow.
Multi-Shuttle Collaboration for Maximum Output
Multiple shuttles can run in parallel within different lanes.
When Shuttle A retrieves goods in Lane 1, Shuttle B can simultaneously store goods in Lane 2.
With intelligent task prioritization, overall warehouse throughput increases by 40%+.
Maximize Warehouse Space — Increase Storage Capacity by 2–3×
The HEGERLS Two-Way Shuttle transforms conventional warehouses into high-density, lane-based storage systems that dramatically increase capacity.
Narrower Aisles = More Pallet Positions
- Shuttle aisle width: 1.2–1.5 m
- Forklift aisle width: 3–4 m
This alone increases storage density by 30–50%.
Vertical Utilization up to 90%+
Supports 10–20 m high racking and precise multi-layer placement.
Turn your warehouse into a true vertical storage powerhouse.
Zero Waste Aisles
The shuttle runs straight inside the rack — no turning radius required, eliminating the wasted space created by forklifts.
Extremely Flexible — Perfect for 90% of Warehouse Scenarios
Whether your warehouse handles food, pharmaceuticals, retail, cold chain, manufacturing, or building materials, HEGERLS shuttles adapt seamlessly.
Cold Storage Ready: -40°C to +50°C
Operate in extreme environments where forklifts and workers struggle.
FIFO & FILO Capable
Ideal for industries with strict batch and expiry controls.
Modular & Scalable Deployment
Start with one lane — expand anytime by adding shuttles or racking.
Grow as your business grows — with controlled investment.
Multi-Load Compatibility
Supports:
- 500–2000 kg pallet loads
- Standard or customized pallet sizes
High ROI & Cost-Effective Automation — Lower CAPEX, Lower OPEX
HEGERLS Two-Way Shuttle provides one of the highest returns on investment among dense storage systems.
Lower Initial Investment
Compared with four-way shuttles or stacker crane AS/RS systems,
Two-Way Shuttle hardware is 20–30% more affordable.
Low Maintenance, Long Service Life
- Fewer wearable parts
- Maintenance cycle: 1–2 years
- Maintenance cost up to 50% lower than forklifts
- Lithium battery supports 8–10 hours with fast charging
Reduce Labor Cost by 70–80%
A 10,000 m² forklift warehouse requires 10–15 operators.
A shuttle-based warehouse needs just 2–3 technicians.
Safety Built In — Protect People, Products, and Operations
HEGERLS prioritizes operational safety with advanced mechanical and electronic protection.
Intelligent Safety System
- Parking, slowing, and obstacle detection sensors
- Emergency braking within 0.5 m
- Anti-collision buffers
- Audible alarms for enhanced awareness
- Strict load and speed limits
Next-Generation Lifting Mechanism
HEGERLS uses a gear-rack lifting design, delivering:
- 30% higher transmission efficiency
- 80% higher structural reliability
- 60% more precise lifting control
- Ensures near-zero failure rate over full life cycle
Adaptable to Harsh Environments
Dust, noise, and temperature fluctuations have minimal effect — a major safety and quality advantage over manual systems.
Ultra-Low Energy Consumption — Build a Greener Warehouse
Electric Drive, Minimal Power Usage
Only 0.5–1 kWh/hour
Over 90% lower carbon emissions than diesel forklifts.
Quiet Operation (< 65 dB)
Ideal for urban warehouses or noise-sensitive environments.
Market Insights Supporting Investment
According to a recent report, the global warehouse automation market size is projected at USD 29.91 billion in 2025, and expected to more than double to USD 63.36 billion by 2030.
Hardware components (such as AS/RS and shuttle systems) accounted for roughly 58% of market share in 2024, though software and service components are now growing faster.
In the retail & e‑commerce segment — which represents about 28% of warehouse automation spend — the pressure for high throughput and dense storage is most acute.
Medium‐sized warehouses (50k‑200k sq ft) represented 37% of the market size in 2024, yet the fastest growth is seen in mega‑sites (>500k sq ft) at ~17.2% CAGR.
These indicators underscore why a system like HEGERLS Two‑Way Pallet Shuttle is not merely “nice to have” but increasingly a strategic necessity for competitive warehousing.
Application Scenarios & Use Cases
Cold‑storage / Frozen Warehouse: With narrow aisles and high storage racks, the shuttle system optimizes space when building costs are high and energy for refrigeration is a major expense.
E‑commerce Fulfillment Center: High number of SKU moves per day demand fast retrieval/replenishment; high density racks save costly floor space near urban centers.
Third‑Party Logistics (3PL) Facility: Flexible operations, multiple clients, varied pallet sizes – the shuttle system’s adaptability and scalability make it ideal.
Manufacturing Supply Chain Hub: Internal logistics benefit from reduced footprint and faster access to materials for just‑in‑time production.
Implementation Process & Timeline
Site Assessment & Layout Planning: HEGERLS engineers review warehouse footprint, throughput requirements, pallet types and integration needs.
System Design & Customization: Shuttle lanes, load capacities, control software integration and safety mechanisms are configured.
Installation & Commissioning: Rail infrastructure installed, shuttle vehicles deployed, software integrated into WMS/WCS, and testing conducted.
Training & Ramp‑Up: Operator training, system fine‑tuning, and gradual ramp‑up to full throughput. Typical lead time from order to commissioning is 12–16 weeks depending on scale.
Ongoing Support & Maintenance: HEGERLS offers service packages including spare parts, predictive maintenance modules and software updates to ensure uptime and performance.
FAQ
Can the HEGERLS two‑way pallet shuttle system handle different pallet sizes and weights?
Yes — the system is configurable for standard and non‑standard pallets. Load capacities up to 1700 kg (or customised as needed) are supported, and the shuttle software can be programmed for varying lane depths and pallet footprints.
How does the system integrate with existing warehouse management software (WMS)?
HEGERLS provides a middleware control interface that links the shuttle hardware with your WMS/WCS. Real‑time status, pallet location tracking, and task assignment are synchronised, enabling seamless operations without replacing your core WMS.
How does a Two-Way Pallet Shuttle improve warehouse efficiency?
- Two-Way Pallet Shuttles:
- Reduce forklift travel inside racking
- Speed up pallet handling cycles
- Support automated or semi-automated workflows
- Reduce manpower requirements
- Enhance safety by minimizing forklift–rack interaction
Many warehouses see 25–40% throughput improvement after adopting shuttle systems.
Can a Two-Way Shuttle work in cold storage?
Yes. Most systems, including HEGERLS Two-Way Shuttles, support –25°C cold environments with:
- Low-temperature batteries
- Anti-frost electronics
- Sealed motor design
Cold storage operators often see the fastest ROI.
Is the system suitable for retrofit into an existing warehouse?
Yes — the modular design allows retrofit into many existing racks and layouts. During assessment, HEGERLS engineers evaluate structural integrity and integration requirements, providing a retrofit plan that minimizes disruption.
Ready to unlock higher storage density and throughput?
Request your free consultation today or explore our pallet shuttle solutions to see how HEGERLS can transform your warehouse operations.
Key words:
Two-Way Pallet Shuttle System,High-Density Warehouse Storage,Automated Shuttle Racking,Warehouse Efficiency Solutions,HEGERLS Pallet Shuttle
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