4-Way Shuttle Automation Solution

A scalable growth platform, engineered by SEC, powered by 4-Way Shuttle automation

Industry: Wholesale/Distribution
Property partner: Ashford Developments
Facility: New 40,000 ft² site
Solution: 4-Way Shuttle Automation Solution

At a glance

• Pallet positions increase from 1,400 to 4,088 (+192%, +2,688 locations)
• 200%+ storage density improvement vs an equivalent APR layout
• 12 4-Way Shuttles across 4 storage levels
• Throughput (designed): 45 pallets/hour per lift, 135 pallets/hour combined inbound/outbound flow
• Order throughput (designed): up to 200 orders/hour per picker, up to 1,000 orders/hour theoretical maximum

The Challenge

The client had outgrown its storage model and needed a scalable route to growth

Trigger for change (client-identified): Rapid growth (30% YoY) created capacity and throughput pressure that the existing storage model could not absorb.

Before engaging SEC, the wholesaler had reached a point where the existing storage approach was limiting growth. The business knew it had to change, but had not yet defined what the future solution should look like, and had not confirmed the right facility size to support long-term operations.

The client needed a partner to convert growth intent into a practical, scalable fulfilment blueprint, with clear requirements to:

• Increase pallet capacity within a workable footprint
• Improve throughput to support higher operational demand
• Avoid a growth model that depends on proportional increases in the workforce
• Build an expansion path to support Phase 2

Key operational constraint: Space constraints and manual process with minimal software utilisation.

The Solution

From site strategy to automation delivery

SEC supported the project from the earliest stage, helping shape the operational blueprint before finalising the site. Working alongside Ashford Developments, SEC helped identify and secure a new 40,000 ft² facility aligned to the growth plan, then designed and delivered an automated storage and fulfilment system centred on a high-performance 4-Way Shuttle solution.

System scope (Phase 1):

12 automated 4-Way Shuttles

4 levels of high-density storage

Lifts (Phase 1): 1

Lanes (Phase 1): 280 minimum (extendable to 504 by splitting lanes)

SKU count: 580 (current)

Software layer – WES (Warehouse Execution System)

Alongside the automation, SEC’s WES connects the client ERP to warehouse execution, pulling order and SKU data, releasing work in the right sequence, and keeping inventory and order status aligned as fulfilment progresses. The WES generates and issues robot tasks through SEC’s orchestration layer, coordinating the robot fleet in line with live demand.

WIS (Warehouse Intelligence System)

SEC’s WIS (Warehouse Intelligence System) is planned as the next layer of capability, providing the connection between the automation environment and the client ERP to enable reliable communication and coordinated execution. It will support dynamic SKU positioning using live forecast data, plus intelligent picking, packing, and put-away user interfaces and workflows.

Early operational testing indicates the system is performing close to its designed throughput, with the current limiting factor being operator’s ramp-up as the customer team completes training.

The Results

Capacity, density, and flow, built for scale

Storage capacity uplift

Pallet capacity increased from 1,400 to 4,088, adding 2,688 pallet locations and delivering an uplift of over 190%. Compared with an equivalent APR layout, the system provides 200%+ improvement in storage density.

High-throughput handling (designed)

The solution is engineered for 45 pallets per hour per lift, equating to 135 pallets per hour in combined inbound and outbound flow. On the order side, it is designed to support up to 200 orders per hour per picker, with a theoretical maximum of up to 1,000 orders per hour across the system.

Operational leverage, without headcount reduction

The project was designed to increase capability rather than reduce the workforce. The existing team can operate a substantially larger site while maintaining the same order-fulfilment KPIs, with automation supporting movement, replenishment, and sequencing so labour can focus on value-adding work.

Phase 2

Planned expansion

Phase 2 will expand overall system capability in line with growth.

Phase 2 start: 2026

Lifts (Phase 2): 3

Lanes (Phase 2): 820 minimum (extendable to 1,580 by splitting lanes)

Phase 2 is scheduled for completion in 2026, expanding the system from 1 to 3 lifts and increasing lane capacity to support continued growth. Together, Phase 1 and Phase 2 provide a scalable foundation for long-term fulfilment performance. If you would like to explore what a phased automation roadmap could look like for your operation, please get in touch.