Comprehensive Analysis & Comparison of Pallet-handling Robots

With the rapid advancement of logistics and warehouse automation, pallet-handling robots have become a crucial solution for improving operational efficiency and reducing labor costs. Otobro presents an overview of various types of pallet-handling robots—their characteristics, application scenarios, advantages, and limitations—to help enterprises choose the most suitable automation equipment.

1. Types of Pallet-Handling Robots

   1. Low-Height Transport Robots

      • These robots are primarily used for short-distance horizontal transport and are suitable for internal logistics in warehouses, supermarkets, and factories.

      • Type	Storage Depth	Load Capacity	Lifting Height	Application Scenarios	Advantages	Limitations	Cost
        Hydraulic Pallet Jack	S	1T	0m	Warehouses, supermarkets, factory-floor transport	Low cost; manual or automatic mode available	Requires manual operation; limited load capacity	$
        Electric Pallet Truck	S	1T	0m	Logistics centers, supermarkets, manufacturing	Electric drive; lightweight; reduces labor effort	No stacking; limited navigation capability	$
        APR TUSK	S	1.5T	0m	3C industry, electronics, precision logistics	Autonomous navigation; integration with AMRs	Ground-only transport; no stacking	$$
        VAN	S	1.5T	11m	Large warehouses, e-commerce, medical logistics	Operates in narrow aisles; maximizes storage	Higher cost; requires high-precision navigation	$$$$

         

   2. Forklift-Type Automated Robots

      • Equipped with lifting capabilities for accessing high racks and handling warehouse goods.

      • Type	Storage Depth	Load Capacity	Lifting Height	Application Scenarios	Advantages	Limitations	Cost
        Forklift AGF	S	1.2T	3-6m	Factory logistics, warehouse distribution, cold storage	Supports high-level stacking and heavy loads	Requires standard navigation (e.g., SLAM, RFID)	$$$

   3. High-Density Automated Storage Robots

      • Used in high-density storage environments and automated vertical warehouses.

      • Type	Storage Depth	Load Capacity	Lifting Height	Application Scenarios	Advantages	Limitations	Cost
        Stacker Crane	S/D	1.5T	40m	Automated vertical storage, cold chains, logistics centers	High automation efficiency; ideal for high-density environments	High cost; best suited for large warehouses	$$$$$

   4. Shuttle Robots

      • Adaptable to different storage models and enhance warehouse space utilization.

      • Type	Storage Depth	Load Capacity	Lifting Height	Application Scenarios	Advantages	Limitations	Cost
        Four-Way Shuttle	Unlimited	1.5T	30m	High-density warehouses, sorting centers	Four-way mobility; high picking flexibility	Requires specific rack designs; specialized use	$$$$
        Two-Way Shuttle	Unlimited	1.5T	30m	Food, beverage, pharma, e-commerce	Lifting module; improved overall storage efficiency	Less flexible than four-way shuttles	$$$
        Mother-Child Shuttle	Unlimited	1.5T	30m	E-commerce, cold storage, sorting centers	High flexibility; child unit rides on mother cart	Best for standardized goods; not for small-lot SKUs	$$$$$

2. Application Scenarios

   Each type of pallet-handling robot suits different warehouse environments

   • Low-height transport robots: For short-distance handling and internal transport in supermarkets, DCs, and factories.
   • Forklift-type robots: For logistics centers and accessing high-level racks, such as cold chain and factory use.
   • Stacker cranes: Ideal for high-density, large-scale automated storage systems.
   • Shuttle robots: Best for automated picking and sorting in food, beverage, and e-commerce logistics.

3. Advantages

   • Increased storage density: Automated handling and efficient picking allow optimal use of warehouse space.
   • Reduced labor costs: Autonomous navigation and smart transport reduce the need for human intervention and improve safety.
   • Adaptability: Robots accommodate a wide range of scenarios, from ground-level transport to high-rack access.
   • Smart management: Seamless integration with WMS (Warehouse Management System) and WCS (Warehouse Control System) enhances operational efficiency.

4. Limitations

   • High initial investment: Procuring and installing automation systems may require significant capital.
   • Site-specific requirements: Some robots need dedicated rack systems or navigation infrastructure, posing adaptation challenges.
   • Maintenance and support: Automated systems require regular maintenance and technical support to ensure stability.

5. How to Choose the Right Pallet Robot?

   1. Consider the following when selecting your automated system

      • Warehouse layout: Flat vs. vertical storage
      • Goods flow: High-frequency dispatch vs. low-frequency storage
      • Cargo type: Standard pallets vs. mixed SKUs in small batches
      • Budget: Low-cost solutions vs. highly intelligent automation systems

6. Conclusion

   • Pallet-handling robots have become an essential part of modern warehouse operations. Selecting the right robot based on your specific needs can significantly enhance logistics efficiency and reduce labor costs. In the future, with the advancement of AI and IoT, these robots will become even smarter—further optimizing supply chain operations.

＊Due to differences across industries and business models, equipment configurations and solutions may vary. For tailored system consultations, please feel free to contact us.