Case Study: High-Density Shuttle Racking for a Leading Drinks Manufacturer
Todds Leap Racking & Shelving recently completed one of our largest racking projects to date for a major international drinks manufacturer based in Northern Ireland. The installation features two massive blocks of Mecalux Pallet Shuttle racking, capable of storing approximately 10,000 pallets of finished goods including cans and bottles weighing up to 1,200kg each.
Working closely with Halgruppen on the warehouse build, and with the Mecalux design and technical team on the racking and automation systems, this project represents a landmark moment for our business — our first automated pallet shuttle system and a milestone in our growth into large-scale, high-density storage solutions.
The Solution
The system comprises:
Two dedicated shuttle racking blocks
Storage up to six pallets high
Lanes between 16–18 pallets deep
Designed for heavy unit loads up to 1,200kg
The use of Mecalux Pallet Shuttle technology allows fast, safe, and highly efficient movement of pallets within the racking, significantly reducing forklift travel time and optimising warehouse throughput.
Why Mecalux Pallet Shuttle?
According to Mecalux, the pallet shuttle system offers several key advantages:
Maximised Storage Capacity: High-density racking allows more pallets per m², ideal for manufacturers with high volume SKUs.
Greater Productivity: Automated shuttles speed up pallet movements, reducing forklift travel and increasing overall efficiency.
Improved Safety: Operators work at the front of the racking rather than driving into lanes, reducing the risk of accidents and rack damage.
Flexibility: Suitable for both FIFO and LIFO operations, ideal for managing different product flows.
Durability: Designed to handle heavy loads consistently, maintaining performance over time.
Project Impact
For the client, this system delivers:
Approx. 10,000 pallet storage capacity within a compact footprint.
Faster order processing thanks to shuttle automation.
Reduced handling costs and increased safety in daily operations.
A future-proof platform for expansion into further racking and automation projects.
Partnership & Future Growth
This project highlights the strength of our partnership with Mecalux, combining their engineering expertise with our local installation and project management capability. It has forged a strong relationship that we look forward to building upon across Ireland and the UK as demand for high-density and automated storage solutions continues to grow.