Project Overview

We are proud to present the high-performance, semi-automated shuttle rack system project for AJ Solution's new, modern warehouse in Paraguay. This project is designed to create a high-density, high-efficiency, and intelligent storage solution that will meet the client's growing logistical demands and significantly enhance their operational productivity. The project is scheduled for full commissioning and handover in March 2025.

Background & Challenges

With rapid business expansion, AJ Solution faced the following core challenges:

Low Storage Space Utilization: Traditional racking systems were insufficient for high-density storage, leading to poor land-cost efficiency.

Need for Higher Throughput: Manual or conventional forklift-based operations created bottlenecks, struggling to meet peak-season order fulfillment.

Demand for Inventory Accuracy: Required precise inventory management and fast stock-taking capabilities.

Labor Costs and Safety: A need to reduce pedestrian-forklift interaction to lower labor costs and minimize safety risks.

The Solution: High-Performance Shuttle Rack System

Our core solution is the implementation of an advanced semi-automated shuttle rack system. This system perfectly balances storage density, operational efficiency, and investment cost.

System Core Components:

Racking Structure: A high-strength steel racking system, designed for stability and durability, providing a secure foundation.

Shuttle Cars (2 Sets): The project will be equipped with two (2) sets of high-performance radio-shuttle cars. These shuttles operate on rails within the racking lanes, automatically handling the storage, retrieval, and positioning of pallets—they are the heart of the automation.

Management System: Integrated Warehouse Management System software for intelligently dispatching shuttle tasks, optimizing pickup and deposit paths, and enabling real-time inventory visibility.

System Workflow:

A forklift operator only needs to place a pallet at the designated entrance of a racking lane. Using a remote control or system command, a shuttle car is dispatched. The shuttle automatically receives the pallet and transports it to the optimal available location deep within the lane for storage. For retrieval, the shuttle brings the requested pallet to the lane entrance for the forklift to collect. This "goods-to-person" principle drastically reduces forklift travel and waiting time within the aisles.

Key Project Parameters

Maximized Space Utilization: The high-density layout increases storage capacity by up to 80% or more compared to conventional selective racking, delivering outstanding land-cost savings.

Significantly Enhanced Efficiency: The two shuttle cars can operate in parallel, enabling fast and accurate load handling. This reduces forklift cycle times and travel distances, leading to a substantial increase in throughput.

Reduced Operational Costs: Minimizes the number of aisles required and dependence on highly skilled forklift drivers, thereby lowering long-term labor and energy costs.

Superior Safety & Stability: The system is engineered for the 1000 kg heavy-load requirement, ensuring structural integrity. Reduced man-machine interaction minimizes the risk of accidents and product damage.

Accurate & Transparent Inventory Management: The system precisely tracks the location and status of every pallet, enabling real-time inventory visibility and accurate stock-taking for better decision-making.

Conclusion

The shuttle rack project for AJ Solution in Paraguay is not merely an upgrade of storage equipment; it is a strategic leap towards intelligent, modern logistics management. Upon successful implementation, this project will establish a highly efficient, reliable, and future-proof distribution hub, powerfully supporting the client's strategic growth in the Paraguayan and broader South American markets.

We look forward to a close collaboration with AJ Solution to ensure the project's successful completion in March 2025, setting a new benchmark for industrial warehousing in the region.