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Optimizing Warehouse Space with Automated Pallet Storage Solutions from Kardex
Challenge: Limited Space – Disrupted Tool Retrieval Processes
ABB Switzerland, one of the world’s leading technology groups in electrification and automation, operates a gas-insulated switchgear (GIS) manufacturing plant in Zurich/Oerlikon with more than 6,500 employees. The assembly tool management department is responsible for storing and retrieving thousands of tool sets used for installation projects worldwide.
Although ABB had already invested in around 20 automated storage modules from Kardex, challenges remained with incomplete tool sets. These were previously stored on pallets in static racking systems, leading to several issues:
- Lack of available storage space
- Difficult handling and movement using forklifts
- Higher risk of errors and delays during material retrieval
Solution: Kardex Shuttle 1000 – Smart Storage, Fast Access
After learning about Kardex’s automated pallet storage solution, ABB decided to invest in two additional Vertical Lift Modules, the Kardex Shuttle 1000, which proved to be the ideal solution to overcome space constraints and improve picking efficiency.
Cấu hình hệ thống:
- System height: 8,850 mm
- Shuttle dimensions: Width 1,850 mm | Depth 1,270 mm
- Total number of trays: 29 trays for double-frame pallets (up to 950 mm high)
- Floor space required: only 18.94 m²
- Integrated OPLogicontrol and connected to more than 20 existing Kardex systems
Learn more: CaseStudy_EN_ABB.pdf
How it works:
- Pallets containing incomplete tool sets—such as diamond drilling tools, repair tools, and precision measuring equipment—are stored in the first Shuttle.
- After use, tools are temporarily returned and stored to the second Shuttle.
- Following quality inspection, the tools are transferred back to permanent storage.
Warehouse staff operate the system via an intuitive touchscreen interface, with a throughput of 20–50 operations per day. Pallets are automatically presented using a tray extractor, allowing safe and efficient handling with electric forklifts.
Results Achieved
| Benefits | Description |
| Space savings | Store 58 pallets in only ~19 m² of floor space |
| Faster retrieval speed | Automated operations with fast, simple retrieval at the touch of a button |
| Optimized workflows | Clearly separated processes for receiving, storing, and returning materials |
| Improved safety and ergonomics | Reduced manual handling, ensuring employee health and well-being |
Conclusion: ABB & Kardex – A Strategic Partnership for a Truly Smart Warehouse
The collaboration between ABB and Kardex once again highlights the significant value of automation in modern industrial storage. The Shuttle 1000 solution not only optimizes warehouse space but also enhances operational efficiency, minimizes errors, and enables ABB to serve global orders with maximum speed and accuracy.
Are you facing challenges with pallet storage, limited warehouse space, or inefficient manual picking processes?
Contact us today to receive expert advice on the most suitable automation solution for your operation.