Empty warehouse with blue metal shelving units and a central aisle.

Semi-Automated Shuttle Racking—Maximum Density, Minimal Forklift Movement

Electrically powered shuttles carry pallets through deep tunnels while forklifts load and pick only at tunnel ends. Increase capacity, cut forklift time inside racks, and reduce damage—ideal for cold stores and high-volume SKUs.

Semi-automated shuttle racking is a high-density storage solution that utilizes electrically powered shuttles to store and retrieve palletized goods within rack tunnels. This system eliminates the need for forklifts to enter the aisles (loading at the end of the rows only), improving storage efficiency and reducing overall operating costs.

Warehouse storage racks with orange and green metal shelving, supporting pallets and boxes, in a large industrial space.

Why Choose Shuttle Racking

  • High-density storage — eliminate internal aisles; add deep tunnels for more pallets in the same footprint.

  • Faster cycles — shuttles move pallets quickly and predictably; fewer forklift movements per pallet.

  • Less rack and pallet damage — trucks stay out of tunnels; impact at the rack face is reduced.

  • FIFO or LIFO — configure tunnels to suit your inventory strategy.

  • NZ compliant — designed and installed to the NZ building code

How It Works 

Operators place the shuttle in a tunnel, load pallets at the tunnel entrance, and the shuttle transports pallets to the next free position. For retrieval, the shuttle brings pallets to the face. Tunnels can be dedicated to FIFO (load one side/pick the other) or LIFO (same-side load/pick). Depth, level spacing, and clearances are set to your pallets, weights, and cooling strategy.

Is Shuttle Right for You?

A strong fit when you have:

  • Many pallets per SKU with repeat orders

  • Chillers/freezers where cubic metres are expensive

  • Targets to cut forklift travel and in-rack damage

  • FIFO requirements on some lines and LIFO on others

Consider alternatives when:

  • Very low pallet counts per SKU (selective)

  • Moderate density without automation (double-deep or drive-in)

We’ll compare options and show the trade-offs.

Our Simple Process

  1. Free site consultation and measure up

  2. Agree a racking plan that works for your business, prepared by our professional AutoCAD designers

  3. Quote for new racking or good quality secondhand.

  4. Install • stay open and operational if required.

  5. Personal, onsite handover to ensure customer satisfaction.

How We Find Your Capacity

  • Complimentary site visit with expert advice from our experienced consultants.

  • Complimentary AutoCAD designs prepared by our professional designers

  • We can then confirm your pallet capacities and numbers of SQU locations

Why Choose Elite Racking

  • Create extra space without moving

  • AutoCAD designs showing pallet and pick location capacities

  • Install around live operations • zone isolation, nights and weekends when needed

  • Clear accountability • direct access to the owners

  • New or good quality second-hand • meet budget and lead times while staying compliant

Assurances

  • Owner led and operated

  • We can manage the entire compliance process for you

  • Phased installations, after hours or full closure

  • Auckland based, and operating NZ wide

Empty warehouse storage racks with orange and green metal shelving, some pallets stored, and a robotic lift mechanism in an aisle.
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Our latest projects

TSS Sensitive Freight

Elite Racking transformed TSS Sensitive Freight warehouse with a custom narrow aisle pallet racking system. Our turnkey solution included design, supply, delivery, and installation, maximizing storage capacity while ensuring safety and compliance.

Semi-Automated Shuttle Racking

Semi-automate pallet shuttle system installed into a commercial freezer and running at negative 18 degrees Celsius. The system achieves an 80% storage utlisation.

Ecolab

Elite Racking recently completed a full-service pallet racking project for Ecolab, delivering a custom-designed system with complete supply, delivery, and installation.
We handled everything — from layout design to full compliance management — ensuring a seamless, stress-free experience for the client. The result: a safe, efficient storage solution delivered on time and to spec.

Click here to view more

What our customers say about us

  • We were thrilled with the pallet racking Elite Racking provided for our warehouse in Botany. Their team was incredibly helpful from start to finish, understanding our specific storage needs and recommending the perfect system. The installation was efficient and professional. We couldn't be happier with the results and would highly recommend Elite Racking.

    Robbie Beilby
    Managing Director
    Target Furniture

  • We were in the market for a vertical storage rack. After contacting and discussing our needs, Elite Racking made a site visit to ensure their solution would meet our needs. After viewing the location and needs a couple of additional suggestions were made, which we adopted. Order placed, and delivery was earlier than expected which was great allowing us to complete the workshop setup. Very pleased with solution and delivery. Will be using Elite Racking again.

    Jason Clarke
    Managing Director
    Teltherm

  • Elite Racking recently completed the design, supply and install of pallet racking into our brand new warehouse in Wiri and we couldn’t be happier. From the offset, they listened to our needs, designed a solution tailored to our specific freight profile, and managed the whole installation process, allowing us to remain focused on our day to day business. The quality of the racking is excellent, the installation laser perfect and the project came in on budget – I highly recommend Gavin, Zach and the team at Elite Racking.

    Jason Tredgett
    General Manager
    TSS Sensitive Freight

  • We recently used Elite Racking for a complete pallet racking solution, and I'm impressed. Elite provided a full turnkey service – from consulting and design through to supply, delivery, and installation. The entire project was completed on time and on budget. Their team was friendly and professional throughout. Their solution is working well for us.

    Max Divers
    Managing Director
    Divers Group

  • Very impressed with professionalism, good advice, great speed of service, came in on time and to budget. Well worth dealing with Elite, highly recommend

    Chris Barnes
    Site Operations Manager
    Nutrimetics

  • We had a fantastic experience with Elite Racking. Their team was incredibly supportive, professional, helpful, and accommodating from start to finish. They took the time to understand exactly what we needed and provided expert advice tailored to our requirements. Communication was clear and efficient throughout, and they delivered everything on time and with great attention to detail. On top of their excellent service, their pricing was very competitive—great value for the quality and support they provide. It's clear they genuinely care about their clients and take pride in their work. Highly recommended!

    May Visethsinh
    Customer Services & Warehouse Supervisor
    Bonson Packaging

Frequently Asked Questions

  • Semi-automated, high-density storage. An electric shuttle moves pallets in deep lanes while forklifts work at tunnel faces.

  • Yes. Configure tunnels for FIFO (load one side/pick the other) or LIFO (same-side load/pick).

  • No. Forklifts stay at the face, which reduces rack damage and speeds up cycles.

  • Yes. Excellent density and reduced forklift time inside chillers/freezers. We specify finishes, anchors, and ventilation/flue spaces for cold rooms.

  • Battery-powered units with remote controls and safety sensors. We provide training, RAMS, and operating procedures.

  • Yes. Designed to AS 4084:2023 with PS1/PS4, seismic/floor checks, and load signage.

  • Often yes—the shuttle hardware is new; the rack structure can be new or certified second-hand if it meets spec and compliance checks.