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 systems—without expanding the warehouse.
Solution Highlights
1. Four-Level High-Density Storage
Zikoo Robotics converted the existing floor-stacked warehouse into a four-level automated pallet storage system.
By utilizing vertical space more effectively, the solution created approximately 1,000 pallet positions within the existing footprint and increased storage density by approximately 70%.
2. One Main Aisle + 12-Deep Storage
The one-main-aisle and 12-deep storage configuration minimizes aisle space and maximizes the area available for pallet storage.
Combined with four-way shuttle technology and multi-level racking, the layout delivers higher storage density without requiring additional warehouse space.
3. Existing Wooden Pallets Reused
The customer's existing wooden pallets were evaluated during the planning stage and incorporated into the solution where suitable.
This reduced unnecessary asset replacement and helped control the overall automation investment.
4. WMS, WCS and ERP Integration
Zikoo Robotics integrated its WMS and WCS with the customer's existing Ostendo ERP, creating a connected workflow:
ERP → WMS → WCS → Automated Equipment
ERP manages business orders, WMS manages inventory and warehouse tasks, while WCS coordinates equipment and task execution.
The customer could therefore retain its existing ERP while achieving integrated warehouse management and automated equipment control.
Zikoo Robotics Automated Warehouse Solution
The project combines four-way shuttle robots, vertical lifts, high-density racking and intelligent warehouse software.
The four-way shuttle robots handle pallet storage and retrieval within the racking system, while two vertical lifts transport pallets between different levels. WMS and WCS coordinate inventory management, task allocation and equipment execution.
Hardware
- 4 four-way shuttle robots
- 2 vertical lifts
- 4-level pallet racking
- 12-deep high-density storage
Software
- WMS:Inventory and warehouse task management
- WCS:Equipment control, task scheduling and monitoring
- Ostendo ERP:Business order and enterprise management
This integrated architecture connects business orders with warehouse operations and automated equipment.
Customer-Centric Warehouse Planning
Rather than applying a standard automation configuration, Zikoo Robotics designed the solution around the customer’s actual warehouse conditions.
The project team assessed SKU characteristics, pallet specifications, inventory levels, inbound and outbound requirements, warehouse space, ERP interfaces, existing assets and investment requirements before finalizing the solution.
This approach helped balance storage density, operational efficiency, system integration and investment cost.
From Floor Storage to High-Density Automation
The project demonstrates how an existing warehouse can be upgraded without expanding its footprint.
By combining four-way shuttle technology, four-level racking, 12-deep storage, vertical lifts and WMS/WCS-ERP integration, Zikoo Robotics helped the Australian packaging company increase storage capacity while reducing labor requirements and improving operational efficiency.
The project reflects Zikoo Robotics’ approach to warehouse automation: 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.
Conclusion
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.
By combining 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.
Related Products
R-Bot
Four-Way Pallet Shuttle
H-Bot
Vertical Two-Way Shuttle
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