Four-Way Shuttle Automated Warehouse Helps Australian Packaging Company Increase Storage Density by 70%
Zikoo Robotics designed and implemented a four-way shuttle automated warehouse solution for an Australian packaging company with more than 46 years of industry experience.
The customer had been relying on traditional floor-stacked storage and manual forklift operations. As inventory volumes increased, limited storage capacity, high labor requirements and low space utilization became major operational challenges.
To maximize storage capacity without expanding the warehouse footprint, Zikoo Robotics developed a four-level, high-density pallet storage system featuring one main aisle and 12-deep storage positions. The solution integrates four-way shuttle robots, vertical lifts, WMS, WCS and the customer’s existing Ostendo ERP.
The completed system provides approximately 1,000 pallet positions, increasing storage density by ~70%, reducing labor requirements by ~80%, and improving overall operational efficiency by ~60%.
Key Project Results
- ~1,000 pallet positions
- ~70% higher storage density
- ~80% reduction in labor requirements
- ~60% improvement in operational efficiency
- 4 four-way shuttle robots
- 2 vertical lifts
- 4-level high-density pallet racking
- 1 main aisle + 12-deep storage
- WMS + WCS integrated with Ostendo ERP
The system enables automated pallet storage, retrieval and transportation while providing centralized warehouse management and equipment control.
Customer Challenges
The customer's traditional floor-stacking warehouse was becoming a constraint on further growth.
Key challenges included:
- Limited storage capacity within the existing footprint
- Low utilization of vertical space
- High dependence on manual forklift operations
- Increasing labor requirements
- Limited warehouse visibility and inventory control
- Lack of connectivity between the ERP system and warehouse equipment
The customer therefore needed a solution that could increase storage capacity, control investment and connect existing business systemscURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
Aspectos destacados de la solución
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El cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limitscURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
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cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
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Hardware
- 4 four-way shuttle robots
- 2 vertical lifts
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Software
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- cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limitscURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
- cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limitscURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
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cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits
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cURL Too many subrequests by single Worker invocation. To configure this limit, refer to https://developers.cloudflare.com/workers/wrangler/configuration/#limits technology should serve the business, and every solution should be designed around the customer’s actual operational needs.
The combination of four-level racking, one main aisle, 12-deep storage and four-way shuttle technology created approximately 1,000 pallet positions within the existing footprint.
At the same time, the reuse of existing wooden pallets reduced unnecessary asset replacement, while the integration of four-way shuttles and vertical lifts reduced dependence on manual material handling.
On the software side, the integration of WMS, WCS and Ostendo ERP connected business orders with inventory management and equipment execution.
The result is a warehouse solution that combines high-density storage, automated handling and digital warehouse management.
Conclusión
From traditional floor stacking to automated high-density pallet storage, this Australian packaging warehouse project demonstrates how an existing facility can be upgraded without expanding its footprint.
Al combinar four-way shuttle technology, multi-level racking, high-density 12-deep storage, vertical lifts and integrated WMS/WCS software, Zikoo Robotics helped the customer achieve:
~70% higher storage density
~80% lower labor requirements
~60% higher overall operational efficiency
~1,000 pallet positions within the existing footprint
More importantly, the project demonstrates a practical approach to warehouse automation: technology should serve the business, and the solution should be designed around the customer’s actual operating environment.
Zikoo Robotics continues to provide intelligent pallet warehouse solutions for customers across different industries and markets, helping businesses unlock additional storage capacity, improve warehouse efficiency and build more connected warehouse operations.
Productos Relacionados
R-Bot
Transbordador de pallets de cuatro vías
H-Bot
Transbordador Vertical Bidireccional
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