Project Overview
This project was delivered for a manufacturing company in Southeast Asia, focused on improving small-parts storage density and order picking efficiency in a medium-sized production warehouse.
- Location: Southeast Asia
- Industry: Machinery Manufacturing
- Warehouse Area: 960 m²
- System Type: CTU (Carton Transfer Unit) Shuttle Racking System
- Racking Height: 6.6 m
- Total Storage Capacity: 16,616 bin locations
- Levels: 17 levels
- Aisle Width: 1.1 m
- CTU Units: 5 CTU shuttles
Customer Challenges
The customer operates a production-oriented warehouse with a wide variety of SKUs and frequent in/out operations.
Key challenges included:
- Large number of small and medium-sized components stored in cartons
- High picking frequency supporting production lines
- Limited warehouse footprint restricting expansion
- Need to balance storage density with picking speed
Traditional shelving systems could not meet the required throughput or space utilization targets.
Our Solution
We designed a customized CTU shuttle racking system based on the customer’s actual operating conditions rather than a standard catalog layout.
Key system features included:
- A 30-meter-long racking structure with a total height of 6.6 meters
- 17 levels of carton storage designed for mixed bin sizes:
- 600 × 400 mm
- 400 × 300 mm
- Each storage level designed for up to 120 kg load capacity
- Narrow aisle configuration with only 1.1 m aisle width to maximize usable space
The system was optimized for stable shuttle movement and continuous picking operations.
Mid-Level Shuttle Passage Design
To further improve operational efficiency, a mid-level shuttle passage was introduced within the racking structure.
- Approximately 5 meters of clear height is reserved below the passage for CTU shuttle operation
- The upper 1.6-meter space is utilized for five additional carton storage levels
- CTU shuttles can switch aisles at mid-distance without traveling the full aisle length
This design reduced shuttle travel distance and improved overall picking efficiency by around 50%, while adding over 400 extra bin locations.
Key Project Highlights
- High-density CTU storage within a compact 960 m² warehouse
- 16,616 bin locations supporting diversified SKUs
- Narrow aisle design maximizing floor space utilization
- Mid-level shuttle passage improving picking efficiency
- Scalable layout suitable for future automation upgrades
Results & Operational Value
The CTU shuttle racking system significantly improved order picking efficiency while maintaining a high level of storage density.
The customer achieved:
- Faster material flow to production lines
- Reduced shuttle travel time
- Improved space utilization without warehouse expansion
The system now supports stable, high-frequency warehouse operations with room for future system expansion.
Why This Project Matters
This project demonstrates our ability to deliver practical CTU shuttle solutions for overseas manufacturing environments, where efficiency, reliability, and space optimization are equally important.
Rather than maximizing theoretical capacity, the system was engineered around real operational needs—ensuring long-term performance and flexibility.
