Ukrainian Logistics Warehouse Four-Way Shuttle AS/RS: 50,000 Pallet Positions at 150 In/Out per Hour

Project Overview

When a large logistics warehouse in Ukraine set out to expand its storage capacity, the original plan was a conventional Automated Storage and Retrieval System (AS/RS). After a detailed review of throughput targets, pallet dimensions and building geometry, the project team and the customer jointly concluded that a four-way shuttle system would deliver far greater density and flexibility. The final solution stores 50,000 pallet positions across 12 levels while moving 150 pallets in and 150 pallets out every hour.

Customer Background

The client is a major logistics warehouse operator in Ukraine serving fast-moving consumer goods, distribution and third-party logistics (3PL) customers. Rapid business growth pushed its manual and semi-automated storage to its limits. Inventory accuracy, labour costs and the ability to scale throughput became critical concerns, driving the decision to invest in a high-density automated warehouse.

From AS/RS to a Four-Way Shuttle Solution

The customer initially specified a traditional AS/RS based on stacker cranes. During the design review we modelled the real pallet profile, the required storage volume and the hourly throughput together with the customer. It quickly became clear that a four-way shuttle system could hit the same throughput in a smaller footprint, with far more flexibility. The customer therefore moved from the original AS/RS concept to a four-way shuttle AS/RS, and the whole layout was re-engineered around this decision.

Key Project Specifications

Throughput and Performance

• Peak hourly flow: 150 pallets inbound and 150 pallets outbound, delivering balanced, continuous operation.
• Monthly volume: 50,000 inbound and 50,000 outbound pallets, comfortably meeting seasonal peaks.
• Storage density: 50,000 positions across 12 levels within a 72 m long building.
• Load handling: stable transport of heavy 1,000 kg pallets measuring 1,200 x 800 x 2,000 mm.

Why the Four-Way Shuttle Won

• Higher storage density than a crane-based AS/RS in the same footprint.
• Flexible, modular capacity that scales lane by lane as volumes grow.
• Multiple shuttles work in parallel for redundancy and higher peak throughput.
• Lower long-term cost per pallet position and reduced energy consumption.

Conclusion

The Ukrainian logistics warehouse project shows how a four-way shuttle AS/RS can outperform a conventional AS/RS when density, throughput and scalability are the priorities. With 50,000 pallet positions, 12 storage levels and a consistent 150 pallet per hour inbound and outbound flow, the facility is now positioned to support the customer's growth for years to come.