Tote Shuttle System
Four models for case and carton handling, from 540 to 2,500 cases an hour. Compare them on payload, case size, sequencing and aisle configuration.
SLS900 Series
Tote Shuttles
All four shuttle models run the same control software and the same rail geometry, so they can be mixed across zones of one building. What separates them is the shape of load they accept, the sequencing they hold, and whether they can leave their aisle. Four differences decide it.
Standard size
Fixed-format handling at the highest rate in the range, 2,500 cases an hour. The fastest choice where your case dimensions are standardized and stable.
Full specification →
Variable size
Takes varying case sizes, 200mm-850mm (L), 200mm-650mm(W) on the same aisle rack, so a mixed or shifting SKU profile needs no mechanical reconfiguration.
Full specification →
Buffer & Sort
Flow-rack operation holding strict first-in-first-out while being replenished behind. Built to buffer and sequence orders immediately ahead of pick stations.
Full specification →
4-Way
Travels across aisles as well as along them. Capacity grows by adding shuttles rather than rebuilding rack, so throughput scales with demand.
Full specification →
Tote Shuttle comparison chart
| Specification | Standard | Variable | Sorting & buffering | Four-directional |
|---|---|---|---|---|
| Max speed | 6 m/s | 6 m/s | 6 m/s | 6 m/s (2 m/s lateral) |
| Payload | 35 kg / 50 kg max | 35 kg / 50 kg max | 3–20 kg | 35 kg / 50 kg max |
| Throughput | 2,500 boxes/hr | ≥1,000 boxes/hr | ≥540 boxes/hr | 1,000 boxes/hr |
| Carton size (L×W×H) mm | 850 × 650 × 500 | 200–850 × 200–650 × 60–500 | 220–600 × 200–400 × 150–500 | 200–850 × 200–650 × 160–500 |
| Acceleration | 2 m/s² | 2 m/s² | 2 m/s² | 2 m/s² |
| Configuration | Single aisle | Single aisle | Single aisle | Multi-aisle |
| Continuous runtime | Unlimited · charges on track | Unlimited · charges on track | Unlimited · charges on track | 168h · self charges during downtime |
The complete system
The complete Tote Shuttle system
Tote shuttles handle every horizontal move inside the rack. Servo lifts carry cases between levels, and interface lines connect the rack to the rest of the building. Throughput is set by how many shuttles and lifts you run rather than by the structure, so density and speed are specified separately.
01 · Box shuttle
Travels the rack on rail, bidirectionally on the Standard, Variable and Sorting & Buffering shuttles, and across aisles on the 4-Way. Positioning to ±3 mm by DC servo, photoelectric and RFID.
02 · Layer-changing lift
Servo belt drive carrying up to 100 kg across two cargo compartments, positioning to ±2 mm, at 6 m/s unloaded.
03 · High-density racking
Multi-deep, multi-level rack from 2 to 30 m tall with aisles from 10 to 100 m long, reconfigurable as the SKU profile changes.
04 · Interface lines and charging
Chain in and out conveyors at the rack face, and a conductor rail running the length of the aisle. Shuttles collect power continuously as they travel, so they never stop to charge.
Where they run
Built for case level operations
E-commerce fulfilment
High line counts, small orders, sharp peaks. Buffering ahead of pack stations is usually the constraint rather than storage itself.
Retail replenishment
Store-order sequencing so cases arrive in the order they will be shelved, which moves labour out of the store and into the DC.
Electronics and manufacturing
Component buffering to the line, with traceability on every movement and strict FIFO on date-sensitive stock.
Pharmaceutical
Chilled case handling with full audit trail, where manual picking accuracy is the risk being engineered out.
Frequently Asked Questions
Tote shuttles, specifically.
How many cases per hour can a tote shuttle handle?
Per-shuttle throughput across this range runs from around 540 to 2,500 cases an hour depending on model and duty cycle. System throughput is a function of shuttle count, aisle layout and lift configuration rather than any single machine, so the meaningful figure comes out of a simulation against your own order profile.
Can one rack handle mixed case sizes?
Yes, on the SLS400 and SLS600, which accept case heights from 60 mm to 500 mm and widths from 200 mm to 650 mm without mechanical reconfiguration. The SLS300 is optimised for a fixed standard format and is faster as a result, so the choice is throughput against flexibility.
What happens to throughput when a shuttle is taken out of service?
The fleet reroutes around it. Because capacity is distributed across many shuttles rather than concentrated in a single crane, losing one unit reduces throughput proportionally instead of stopping the aisle. Units can be removed and replaced without powering down the rack.
Do the shuttles need to stop to recharge?
Not on the Standard, Variable and Sorting & Buffering models, which draw power continuously from the running track and never leave the aisle. The 4-Way shuttle carries its own power for cross-aisle travel and runs 168 hours between charges. It makes at’s way to the charging station and self-charge when not in use.
Can shuttles be retrofitted into an existing warehouse?
In most cases, yes. Our systems are designed to work within an existing building envelope, which avoids the cost and lead time of new construction. The limiting factors are usually clear height, floor flatness and column spacing rather than footprint.
How long does it take from contract to delivery?
100 days from contract for standard configurations. Commissioning time on site depends on system size and how much of the building has to stay operational during installation.