Carton Shuttle System

A Carton Shuttle System is a high-speed automated storage solution designed to handle cartons or totes efficiently within a dense racking structure.

Using shuttles that operate independently on each storage level, the system enables fast storage and retrieval of cartons while maintaining high throughput. This makes it ideal for fulfillment operations with high order volumes, fast picking requirements, and a large number of SKUs.

A Carton Shuttle System consists of multi-level racking where each level is served by a high-speed shuttle that moves cartons or totes within the storage lanes.

When an order is released, the system assigns tasks to the appropriate shuttle, which retrieves the required carton and delivers it to a lift or conveyor. From there, cartons are transferred to picking, packing, or sorting stations.

System configuration—including number of levels, shuttle quantity, lift capacity, and workstation design—is tailored based on SKU profile, order patterns, and throughput targets.

This setup enables fast, accurate, and scalable carton fulfillment.

System Structure

Carton Shuttle Systems typically include:

• Multi-level racking structure – designed for carton or tote storage
• Shuttle units – high-speed devices operating on each level
• Vertical lifts – transferring cartons between levels
• Conveyor interfaces – connecting storage to picking and packing
• Control software (WCS/WMS) – managing task allocation and flow

Optional features and enhancements include:

• Multiple shuttles per level for higher throughput
• Goods-to-Person picking stations
• Order buffering and sequencing logic
• Integration with WMS and order management systems
• Performance monitoring dashboards