As warehouse automation continues to grow, pallet shuttle racking systems have become one of the most popular solutions for high-density, unitized pallet storage.
Compared with traditional drive-in racking, pallet shuttle systems offer higher operational efficiency, improved safety and stability, and significantly better space utilization-up to 80%. Thanks to their flexibility, shuttle systems can handle pallets of different sizes, making them an increasingly preferred choice for modern warehouses.
However, in a pallet shuttle racking system, the pallet itself plays a critical role. The pallet’s material, size, and structural design directly affect system safety, stability, and long-term performance.
1. Pallet Material Selection
Pallets commonly used in warehouses are made of steel, wood, or plastic, each with its own characteristics.
Advantages:
Extremely high strength and load capacity
Excellent impact resistance
Disadvantages:
Higher cost
Risk of corrosion if surface protection is inadequate
Application:
Steel pallets are mainly used for heavy-duty or special applications and are less common in pallet shuttle systems.
Advantages:
Cost-effective
Easy to repair
Disadvantages:
Not fire-resistant or moisture-resistant
Prone to rot, mold, or insect infestation during long-term storage
Application:
Wood pallets are not recommended for humid environments or long-term high-density storage.
Advantages:
Long service life
Moisture- and corrosion-resistant
Recyclable and environmentally friendly
Disadvantages:
Lower rigidity and impact resistance compared to steel
More sensitive to structural design and dimensional accuracy
Temperature range:
Typically -25°C to 40°C
Too low: pallets may become brittle
Too high: pallets may soften and lose load capacity
Summary:
In pallet shuttle racking systems, plastic and wood pallets are the most commonly used options, with the final choice depending on warehouse environment, storage duration, and product characteristics.
2. Pallet Size Requirements
Common international pallet standards include:
Euro pallets: 1200 × 1000 mm or 800 × 1200 mm
Japanese pallets: 1100 × 1100 mm
US pallets: 1219 × 1016 mm (40″ × 48″)
In many markets, pallet sizes are not fully standardized, and variations between manufacturers are common. This increases the complexity of racking system design.
Since pallet shuttle racking is an upgraded version of drive-in racking-where the shuttle replaces forklifts to operate inside the rack-pallet size control is especially critical.
Recommended design principles:
The pallet must fit within the shuttle’s allowable handling dimensions
System design should be based on the largest pallet size
If the largest pallet can be handled safely, smaller pallets are usually compatible as well
3. Pallet Structure and Design
Wooden Pallets
Common wooden pallet designs include:
Type 1: Two-way entry, double-face pallet
Type 2: Four-way entry, single-face pallet
Type 3: Two-way entry, double-face pallet
Type 4: Two-way entry, single-face pallet
Suitability:
Types 1, 2, and 3: Suitable for pallet shuttle racking
Type 4: Insufficient bottom support and not recommended for pallet shuttle systems
Plastic Pallets
Types 1, 2, 3, and 4: Suitable for pallet shuttle racking
Types 5 and 6: Not suitable for direct use in racking systems
⚠ Important note:
For grid-style plastic pallets, the designated support foot areas must either:
Be covered with opaque material, or Be fully covered by the load
If not, the shuttle’s photoelectric sensors may detect light passing through the pallet, causing positioning errors and operational issues.
Conclusion
In pallet shuttle racking systems, pallets are not just load carriers-they are an integral part of the automation system. Selecting the right pallet material, size, and structure is essential for ensuring operational efficiency, safety, and long-term system reliability.
During the planning stage, it is strongly recommended to work with an experienced racking supplier to match the pallets with the shuttle model, warehouse conditions, and stored goods, ensuring stable and efficient operation throughout the system’s lifecycle.