Also called shuttle for pallets or storage shuttle, The system operates within compact structures with rails, moving pallets. in a semi-automatic or automated way for deep positions, without the forklift needing to enter the channels..
The result is a more efficient, safer, and more agile operation, whether in dry warehouses, cold storage facilities, or high-volume distribution centers.
In this article, you will understand how the system works, when it makes sense for your operation, and how it differs from conventional drive-in theaters.
How does the satellite pallet truck work?
THE A satellite car is an electric vehicle. which moves on rails installed inside the channels of the storage structure.
It can operate semi-automatically or integrated into automated systems, receiving commands via remote control, tablet with Wi-Fi connection, or directly through the WMS.
The process is simple:
- The forklift positions the satellite car at the entrance of the desired channel.
- The operator transmits the command via remote control or tablet.
- The cart lifts the pallet and moves it to the first available position, respecting the spaces between loads.
- After depositing the pallet, the cart returns to its initial position, awaiting the next command.
- The forklift never enters the channels: all internal movement is done by vehicle.
In addition to storage and retrieval functions, Bertolini's satellite cart performs automatic pallet inventory by channel using overhead sensors, allowing for precise real-time stock visualization.
Does the satellite car operate in FIFO or LIFO mode?
Both. And this flexibility is one of the system's strengths.
- FIFO (First In, First Out): The first pallet in is the first pallet out. Ideal for perishable goods, food, pharmaceuticals, and any operation requiring expiration date control. To operate in FIFO (First In, First Out), the structure uses two access aisles: one for entry and one for exit.
- LIFO (Last In, First Out): The last pallet inserted is the first to be removed. Suitable for buffer stock operations, where turnover follows a replenishment logic and there is no requirement for an order of departure.
The choice between FIFO and LIFO depends on the product profile and the workflow. An expert can help determine which configuration is most efficient for your specific needs.
Satellite car vs. conventional drive-in: what's the real difference?
This is one of the most common questions when evaluating the system. The answer involves selectivity, security, and operational efficiency.
Node Conventional drive-in, The forklift enters the internal aisles to position or remove pallets. This limits selectivity: an entire aisle needs to be cleared before relocating products, which favors the so-called honeycomb effect, where positions are blocked by loads that have not yet been removed.
With the satellite car, each channel can be operated independently. It is possible to store a different SKU per channel within the same street, which can increase selectivity by 3 to 5 times compared to conventional drive-ins, as indicated on the Bertolini product page.
Other relevant points in the comparison:
- Security: Without forklifts in the channels, the risk of collision with columns and stringers is virtually eliminated.
- Speed: The satellite vehicle operates at up to 35 m/min with a load, while the forklift in a conventional drive-in system covers the same distances at a lower speed.
- Parallelism: While the truck is moving the pallet, the forklift operator can already manage the next one, reducing cycle time.
- Maintenance: Without the need for forklifts to move around inside, structural wear is considerably reduced.
The drive-in satellite car is, in practice, a direct evolution of the conventional system, with the same high-density principle, but with more control, more safety, and more flexibility.
For which operations is the satellite vehicle most suitable?
The system is versatile, but delivers more value in specific scenarios:
- High storage density with low variety of SKUs per aisle.
- Seasonal operations that require large-volume stock buffers
- Cold storage rooms and temperature-controlled environments (equipment operates down to -30°C)
- Industries and distribution centers with a high volume of homogeneous pallets.
- Operations that need to migrate from conventional drive-in to an intermediate level of automation.
When the product mix is very varied and the turnover is high across different SKUs, systems such as conventional pallet racking or push-back racking may be more suitable.
The right choice depends on a technical analysis of the layout, inventory profile, and operational volume.
Bertolini Storage Systems brings together four automation solutions that can be combined or implemented independently, according to the needs of each operation.
And the satellite car is one of the pieces of this ecosystem.
Access the exclusive infographic: 4 automation solutions to evolve your warehouse like never before.!FAQ – Frequently asked questions about satellite car
-
Does the satellite car replace the conventional drive-in?
It doesn't necessarily replace it, but it's a direct evolution. The satellite car uses the same high-density logic as the drive-in, but with automated internal movement, more selectivity per channel, and without forklifts entering the internal aisles.
-
What is the payload capacity of the satellite car?
Capacity varies depending on the model and design. In general, pallet shuttle systems support loads of up to 1,500 kg per pallet. Correct sizing must be validated by a specific technical design for each operation.
-
Does the satellite car operate in a cold storage chamber?
Yes. The system operates at temperatures down to -30°C, making it especially suitable for cold storage facilities, dairies, food distributors, and any operation requiring strict temperature control.
-
Is it possible to integrate the satellite vehicle with the WMS?
Yes. The Bertolini system allows direct integration with the WMS via Wi-Fi, in addition to operating via remote control or forklift panel. Integration with the WMS automates inventory by channel and increases control over movements.
-
How many satellite vehicles are needed per structure?
It depends on the number of lanes, the volume of traffic, and the operational configuration. In more complex projects, multiple vehicles can operate simultaneously on different streets, increasing the number of cycles per hour.
-
Is it possible to migrate from conventional drive-ins to satellite cars?
In many cases, yes. The storage structure can be adapted by adding rails and stringers to accommodate the satellite car, without the need for a complete replacement of the existing installation.
More than just storage, save up to 50% with a customized project for your company.
Operations migrating from conventional systems to satellite vehicles report significant reductions in labor costs, travel time, and structural maintenance.
A well-designed project can reduce operating costs by up to 50%, depending on volume, current layout, and the degree of automation adopted.
At Bertolini, every solution begins with a detailed analysis of the operation: Layout, inventory profile, pallet flow, and growth objectives. The result is a customized project, with simulations of real gains and projections of return on investment.
Speak to our experts. Discover the potential cost savings that a shuttle storage solution can generate for your warehouse.
