Project Overview
This project was delivered for a textile manufacturing company in Turkey, specializing in fabric and roll material storage.
The customer aimed to significantly increase storage capacity and handling efficiency within a limited warehouse footprint while managing heavy unit loads.
- Location: Turkey
- Industry: Textile Manufacturing
- Warehouse Area: 1,000 m²
- System Type: Four-Way Shuttle Racking System
- Racking Height: 5.5 m
- Storage Levels: 5 levels
- Total Storage Positions: 578 locations
- Unit Load: 1.0–1.5 tons per load
- Load Carrier: Steel containers
- Container Size: 1,200 × 1,400 mm
Customer Challenges
The customer’s existing fabric warehouse faced several structural and operational constraints:
- Heavy fabric rolls with unit weights up to 1.5 tons
- Limited warehouse height restricting traditional high-bay solutions
- Insufficient floor bearing capacity for dense heavy-duty racking
- Labor-intensive handling resulting in low efficiency and high operating cost
A conventional selective racking system could not meet the combined requirements of load, density, and safety.
Our Solution
We designed a custom four-way shuttle racking system specifically adapted to textile roll storage and heavy unit loads.
Key solution features included:
- Dense five-level racking structure with a total height of 5.5 meters
- Four-way shuttle operation enabling flexible horizontal movement and efficient access to all storage positions
- Steel container-based storage ensuring stable handling of fabric rolls
- High load-bearing design supporting up to 1.5 tons per position
Floor Reinforcement Design
Due to limited floor bearing capacity, a ground beam reinforcement system was integrated into the racking foundation.
- Reinforced beams were installed beneath the racking structure
- Load distribution was optimized to spread concentrated weight across the warehouse floor
- The solution ensured long-term structural safety under nearly 1,000 tons of total stored load
This reinforcement allowed the customer to upgrade storage capacity without costly floor reconstruction.
Key Project Highlights
- High-density four-way shuttle storage within a 1,000 m² warehouse
- Heavy-duty design for fabric rolls up to 1.5 tons
- Ground beam reinforcement improving floor load capacity
- Reduced manual handling and improved operational safety
- Flexible shuttle operation supporting future expansion
Results & Operational Value
After implementation, the warehouse achieved a substantial improvement in both capacity and efficiency:
- Storage capacity increased significantly within the same footprint
- Shuttle-based handling reduced manual labor and handling risk
- Safer, more organized storage for heavy fabric materials
- Improved throughput supporting continuous production demand
The system now provides a stable and scalable storage backbone for the customer’s textile operations.
Why This Project Matters
This project demonstrates our ability to deliver heavy-duty four-way shuttle racking solutions for textile manufacturing environments where load, space, and floor conditions are critical constraints.
By combining structural reinforcement with intelligent shuttle operation, the solution balances storage density, safety, and efficiency—without excessive automation complexity.
