VietPOS Rack 1500 pallet: Storage density increased by 300%

Shuttle rack is a semi-automated storage system that combines deep pallet racking with autonomous shuttles operating within the channels, automatically transporting pallets without requiring forklifts to enter the channels. In Vietnam, this technology is being widely deployed in manufacturing plants, logistics centers, and distribution chains to optimize warehouse space and reduce operational costs.

Customer: Tân Phát Mechanical Manufacturing Company | Industry: Industrial component manufacturing | Scale: 8,500m² warehouse | Location: Thuận An Industrial Park, Bình Dương

Customer Problem: Overloaded drive-in warehouse, slow picking

Before deploying VietPOS Rack, Tân Phát Company used a traditional drive-in system with 3 electric forklifts. Storage density reached only 60-65%, with an average picking time of 8-10 minutes per pallet because forklifts had to drive deep into the channels and perform manual loading and unloading. Each day, the warehouse processed 150-180 pallets, but efficiency was limited by forklift congestion and labor accidents related to driving into deep channels.

• Low storage density: 60-65% of warehouse capacity used; 35-40% of space wasted due to forklift channel width.
• Slow picking: Average 8-10 minutes per pallet; forklifts had to drive deep in, locate positions, and load/unload manually.
• High operational costs: 3 electric forklifts, 6 shift drivers, periodic maintenance — monthly costs of 45-50 million VND.
• Safety risks: Average 2-3 collisions per month in the channels, employee injuries.

Deployed VietPOS Rack Solution: Shuttle rack 1500 pallets

Việt Đức Trí Group collaborated with Tân Phát Company to design a 2-level, 12-channel shuttle rack system, with each channel holding 40 pallet positions (depth 40), for a total capacity of 1,500 pallets. The system includes: (1) high-density pallet rack (5-level frame), (2) 24 automated shuttle carts (12 channels × 2 carts/channel), (3) remote-controlled tugger, (4) WMS coordination system integrated with VietPOS Software.

The deployment process follows 4 steps:

1. Design & Positioning: Survey the current warehouse, create CAD drawings, optimize channels, levels, and electrical cabinet positions. Duration: 3 weeks.
2. Rack & Shuttle Production: Manufacture rack frames and shuttle carts at Việt Đức Trí Group’s factory in Tây Ninh. Quality inspection for each unit. Duration: 8 weeks.
3. Installation & Configuration: Install frames, shuttle carts, electrical system, sensors, and integrate WMS. Train 12 operators. Duration: 4 weeks.
4. Testing & Optimization: Run 500 test cycles, adjust shuttle speed, optimize picking process, standardize WMS data. Duration: 2 weeks.

The system is integrated with VietPOS Software 2026 featuring an automated Warehouse Management System (WMS) module, enabling:

• Shuttle cart dispatching using optimized algorithms (FIFO, LIFO, zone-picking).
• Real-time tracking of pallet locations, cart status, and cycle time on the dashboard.
• ERP data integration for automated picking & put-away commands.

Achieved Results: 300% increase in density, 45% reduction in picking time

After 14 months of implementation, Tan Phat Company has recovered 85% of the investment cost (~ 2.8 billion VND). Full ROI is expected within 18 months thanks to operating cost savings, increased throughput, and reduced pallet damage (from 2-3% down to 0.5%).

Customer Testimonial

“Previously, our warehouse was the ‘bottleneck’ of the entire production. Every day, customers complained about delivery times. After deploying VietPOS Rack, throughput doubled, employees no longer had to run into deep aisles, and safety improved significantly. In particular, the WMS system from VietPOS Software helped us manage inventory accurately, reducing picking errors from 3% to 0.2%. This was a sound investment for the future.”

— Mr. Nguyen Van Hung, Technical Director, Tan Phat Company

Comparison: Shuttle Rack vs Drive-in vs AS/RS

Shuttle rack is a balanced solution between drive-in (low cost, flexible) and AS/RS (high performance, high cost). It is most suitable for small and medium enterprises, or factories needing to increase throughput without investing in a full AS/RS system.

Lessons for Other Businesses

From the case of Tan Phat Company, VIET DUC TRI GROUP drew 3 main points when deploying shuttle rack:

1. Thorough Survey Before Design: Not every warehouse is suitable for shuttle rack. It is necessary to analyze SKU mix, seasonality, product characteristics, and current picking processes. If the goods are slow-moving or require strict FIFO, shuttle rack is the optimal choice.
2. Integrate WMS from the Start: Shuttle rack is not effective without an automated management system. VietPOS Software WMS allows coordinating shuttle vehicles using optimal algorithms, avoiding conflicts, and reducing cycle time. This is a decisive factor for ROI.
3. Employee Training & Process Optimization: After installation, 2-4 weeks of trial runs are needed to standardize processes, adjust shuttle speed, and optimize zone-picking. Operating staff need thorough training on the control system and WMS.

Deployment Support from VIET DUC TRI GROUP

VIET DUC TRI GROUP provides a comprehensive shuttle rack deployment package:

• Design & Consulting: Warehouse survey, CAD drawings, ROI calculation, plan comparison.
• Manufacturing & Inspection: Fabrication of racks and shuttle vehicles at the Tay Ninh factory, 100% quality inspection.
• Installation & Configuration: On-site installation, integration of VietPOS Rack catalogue 2026, customized WMS configuration.
• Training & Support: Training for 3-5 employees, 24/7 support for the first 6 months, periodic maintenance.

Frequently Asked Questions

1. Is shuttle rack suitable for cold storage?

Yes. Shuttle rack is an optimal solution for cold storage because it eliminates the need for forklifts to enter deep aisles (reducing heat loss). The shuttle vehicle is designed to withstand temperatures from -18°C to -25°C. Cold storage operating costs are reduced by 25-30% due to fewer forklifts and shorter cycle times.

2. What is the ROI period for shuttle rack?

Typically 18-24 months, depending on warehouse scale and current throughput. If the warehouse handles 200+ pallets/day, ROI can be shortened to 14-16 months. Tan Phat Company achieved 85% capital recovery within 14 months thanks to a 110% increase in throughput and a 35% reduction in operating costs.

3. Is it necessary to replace all forklifts when deploying shuttle rack?

Not necessarily. You can keep 1-2 forklifts for tasks outside the shuttle rack (receiving, loading/unloading, maintenance). Shuttle rack only requires 1 remote-controlled tugger to assist with putting/picking at the aisle exit. The number of forklifts is reduced by 60-70%.

4. Is shuttle rack compatible with other WMS besides VietPOS Software?

Yes, but API integration is required. VietPOS Software WMS is specifically designed for Việt Đức Trí Group’s shuttle rack, supporting shuttle vehicle coordination via optimal algorithms and real-time monitoring. If using another WMS, additional integration costs range from 200-400 million VND.

5. How is shuttle rack maintained? What is the annual cost?

Shuttle rack requires periodic maintenance: checking motors, batteries, sensors (quarterly), lubrication, and piston replacement (annually). Annual maintenance costs are approximately 8-12% of the system value (~ 224-336 million VND for a 1,500-pallet system). Việt Đức Trí Group offers comprehensive maintenance packages at fixed prices.

Are you looking for a solution to optimize your warehouse? Contact Việt Đức Trí Group for a free consultation and a shuttle rack demo, such as the Tan Phat Company case. Hotline: 0935 295 337 | Email: [email protected]