High‑Density Shuttle Systems: Beyond Traditional Racking

Written By Adrienn Balazs

As New Zealand businesses face increasing demands for warehouse efficiency, safety, and flexibility, many are turning to high-density storage solutions that go far beyond traditional racking. At the forefront of this transformation is the Dexion HDS Shuttle System—a semi-automated, high-capacity storage innovation that optimises both space and operational flow.

Whether you’re a 3PL provider, cold storage facility, or a high-volume FMCG warehouse, this solution is designed to streamline how you store and move palletised goods.


What Is a High-Density Shuttle System?

The Dexion HDS Shuttle System is a radio-controlled, semi-automated solution that moves pallets in and out of storage lanes without the need for forklifts to enter the racking structure. A shuttle device travels on rails underneath the pallets, carrying them deep into the storage channel with speed and precision.

Operators control the system via a handheld RF remote. Once the shuttle is placed at the correct level by a forklift, it takes over the task of storing or retrieving pallets—safely, reliably, and without disrupting other inventory.


Key Benefits of Shuttle Systems Over Traditional Racking

✅ Maximum Storage Density

Traditional drive-in or selective racking requires significant aisle space and limits how deep pallets can be stored. In contrast, shuttle systems can store pallets up to 40+ positions deep, significantly increasing warehouse capacity—up to 25% more compared to standard layouts.

✅ Safer and More Efficient Operations

Since forklifts no longer need to drive into racking lanes, the risk of structural damage or operator injury is dramatically reduced. This also leads to less maintenance and downtime, ensuring smoother operations.

✅ Flexible FIFO/LIFO Inventory Management

Dexion's shuttle systems can be configured for either First-In-First-Out (FIFO) or Last-In-First-Out (LIFO) workflows. This flexibility makes them ideal for a wide range of industries, including:

  • Food & Beverage

  • Cold Chain Logistics

  • 3PL Warehousing

  • Retail Distribution

  • Manufacturing

✅ Labour & Time Savings

The shuttle handles repetitive pallet movement inside the racks, reducing forklift travel time and allowing staff to focus on high-value tasks. This results in faster order picking and more efficient warehouse throughput.


Built for NZ Warehouses: Dexion Shuttle System Features

Here’s what sets Dexion’s HDS Shuttle System apart:

  • Load capacity: Up to 2,000kg per pallet

  • Operating Temperature: From -35°C (cold stores) to +50°C (ambient)

  • Speed: Up to 70m/min (unloaded), 35m/min (loaded)

  • Safety Sensors: Built in obstacle detection and automatic breaking

  • Scalability: Easily add more shuttles as storage needs grow

  • System Integration: Compatible with WMS, ASRS, and conveyor systems

Dexion High Density Shuttle system

Real-World Applications in New Zealand

New Zealand industries are already seeing the impact of shuttle technology. In logistics hubs across Auckland, Dexion’s HDS Shuttle is helping:

  • Cold chain warehouses reduce forklift traffic in sub-zero conditions

  • 3PL providers optimise their space without expanding facilities

  • High-volume FMCG suppliers maximise density while maintaining fast picking access

Fonterra, one of New Zealand’s largest food exporters, has successfully implemented shuttle systems to streamline large-scale pallet storage with minimal floor space usage.

Why Work with Dexion Auckland?

At Dexion Auckland, we don’t just supply racking—we deliver fully integrated storage solutions. With decades of experience, we help clients:

  • Design systems that suit their space and growth trajectory

  • Navigate compliance and safety standards (AS4084, WorkSafe NZ)

  • Maintain and inspect racking for long-term performance

  • Integrate shuttle technology with Dexion’s broader ecosystem, from static shelving to warehouse automation

Is Shuttle Storage Right for You?

If your warehouse is running out of space or struggling with inventory access and safety concerns, a shuttle system could be the key to unlocking:

  • More storage without a bigger footprint

  • Safer and faster forklift operations

  • Smart, scalable infrastructure for the future

Get in Touch

Want to explore whether a high-density shuttle system is the right fit for your business?
📩 Contact us today to book a consultation with our storage experts.

Let us help you design the future of your warehouse—one that’s smarter, safer, and ready to grow.

Adrienn Balazs