AutoSAT is a semi-automated pallet shuttle solution that uses a racking system similar to drive-in, but with one key difference: a motorised shuttle carrier handles all pallet movement inside the channel, so the forklift never needs to enter the rack structure.
Pallets are moved in and out using the shuttle, which runs up and down each channel on dedicated rails. On put-away it places each pallet in the next available position; on retrieval it brings the front pallet to the rack face. Operations can run in manual mode, handling one pallet at a time, or in automatic mode where the operator selects and confirms the number of pallets to be handled in sequence.
The shuttle is placed into the chosen channel by forklift or reach truck and controlled via a handheld remote operated from within the cab. Remotes can operate independently or sync with your Warehouse Management System (WMS) for integrated inventory control. Shuttles are powered by lithium batteries providing a full shift of operation, and are easily swapped or charged via a standard 240v power source. AutoSAT can be configured for both FIFO and LIFO operation.
The two main advantages over traditional drive-in racking are storage density and time savings. With a conventional drive-in system, the forklift and operator enter the rack structure to place or retrieve every pallet – a slow process that also increases the risk of rack damage. With AutoSAT, the shuttle handles that function independently. While it completes the task, the forklift operator is free to move pallets elsewhere in the warehouse. Each time they return to the rack face, the next pallet is already waiting, or the shuttle is ready to accept another put-away.
Storage density is maximised by removing the need for access aisles between every lane. Each block of storage can have different channel depths matched to the number of pallets held per SKU or batch, so you use only the space you actually need and reduce the distance the shuttle travels with each movement.
The shuttle is placed into the chosen channel by forklift or reach truck and controlled via a handheld remote operated from within the cab. Remotes can operate independently or sync with your Warehouse Management System (WMS) for integrated inventory control. Shuttles are powered by lithium batteries providing a full shift of operation, and are easily swapped or charged via a standard 240v power source. AutoSAT can be configured for both FIFO and LIFO operation.
The two main advantages over traditional drive-in racking are storage density and time savings. With a conventional drive-in system, the forklift and operator enter the rack structure to place or retrieve every pallet – a slow process that also increases the risk of rack damage. With AutoSAT, the shuttle handles that function independently. While it completes the task, the forklift operator is free to move pallets elsewhere in the warehouse. Each time they return to the rack face, the next pallet is already waiting, or the shuttle is ready to accept another put-away.
Storage density is maximised by removing the need for access aisles between every lane. Each block of storage can have different channel depths matched to the number of pallets held per SKU or batch, so you use only the space you actually need and reduce the distance the shuttle travels with each movement.
Maximises warehouse cubic space by enabling deep-lane storage.
Reduces the number of forklift aisles required.
Can significantly increase pallet positions compared to conventional selective racking.
Forklifts remain at the aisle face instead of entering racking lanes.
Reduces rack damage, product damage, and operator risk.
Equipped with sensors, safety systems, and emergency stop functions.
Automated pallet movement speeds up loading and unloading.
Supports both FIFO and LIFO inventory management.
Single shuttles can handle up to 25 pallets/hour, depending on the application.
Reduces the need to move other pallets first, a common limitation of drive-in racking.
Shuttle can be directed to any channel independently.
Retrieves or places pallets without disrupting stock in adjacent channels.
AutoSAT is available in several options depending on your environment and integration requirements:
Standard – Our standard model, suited to ambient environments where WMS connectivity is not required. Operated via handheld remote control and suitable for most general warehouse applications.
Below Zero (BZ Model) – Specifically designed for environments that are below zero degrees. This shuttle can operate in temperatures to -30 deg without impacting performance. With special protection for the battery and parts, this model has been designed for optimal performance in freezer conditions.
Stainless – Designed to meet the needs of the dairy and food sector, it has a completely stainless-steel structure and top to ensure it is washable to maintain the high hygiene standards required by the food sector.
Wi-Fi – Equipped with Wi-Fi communication, this unit communicates directly with your WMS which eliminates the needs to be operator control using remote controls
AutoSAT is available in several options depending on your environment and integration requirements:
Standard – Our standard model, suited to ambient environments where WMS connectivity is not required. Operated via handheld remote control and suitable for most general warehouse applications.
Below Zero (BZ Model) – Specifically designed for environments that are below zero degrees. This shuttle can operate in temperatures to -30 deg without impacting performance. With special protection for the battery and parts, this model has been designed for optimal performance in freezer conditions.
Stainless – Designed to meet the needs of the dairy and food sector, it has a completely stainless-steel structure and top to ensure it is washable to maintain the high hygiene standards required by the food sector.
Wi-Fi – Equipped with Wi-Fi communication, this unit communicates directly with your WMS which eliminates the needs to be operator control using remote controls
| Feature | AutoSAT Semi-Automated | Fully Automated ASRS |
|---|---|---|
Forklift Required | Yes | No |
Initial Investment | Lower | Higher |
Storage Density | Very High | Very High |
Scalability | Excellent | Excellent |
Labour Requirement | Moderate | Low |
Automation Level | High | Full |
Drive-in racking requires a forklift to physically enter the channel to place or retrieve pallets, which is slow and creates a high risk of rack damage. AutoSAT uses a motorised shuttle inside the channel, so the forklift stays in the aisle. It also offers FIFO operation, which drive-in cannot.
This is entirely dependent on the number of pallets you move each day. Part of the scoping stage is working out your throughput and then we can estimate based on time and motion, how many you require. Even for companies with a low throughput, we always recommend at least 2 units, so you have redundancy if something was to happen to one of the units.
Yes, we have a specifically designed shuttle called the BZ model which stands for below zero. This shuttle has a special “red box” battery that is inserted into the shuttle while the lithium battery is removed for charging. This keeps the sensors and electronic components at working temperature
Yes, we have a specific model that has inbuilt Wi-Fi that enables it to communicate directly with your WMS removing the need for it to be operated manually by the remote.
One of the benefits that makes this more user friendly than Drive In racking is that the system can be configured for both FIFO and LIFO. Drive in racking is purely set up for LIFO.
As per the Australian Standard (AS4084:2023), pallet racking audits are now mandatory and must be completed every 12 months.
Ensure your facility is safe and fully compliant with a free onsite audit from our expert team.
