Maximize cubic storage capacity up to 80%, slash forklift transit times, and unlock flexible ROI without the prohibitive CapEx and software rigidity of fully automated AS/RS cranes.
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Motorized Mobile Racking: 100% Selectivity at Double Density
Eliminate idle aisles. DEXION RACKING MOVO electronic mobile bases open picking corridors on demand via smart radio control.
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Goods-to-Person Storage Machines
Reclaim up to 75% of shop-floor area while elevating picking accuracy beyond 99.4% through ergonomic vertical lift modules.
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Non-Disruptive Warehouse Modernization
Upgrade legacy static racks into automated shuttle lanes phase-by-phase without suspending live fulfillment operations.
Contact UsWhy are global supply chain directors, industrial real estate asset managers, and 3PL operators consistently prioritizing semi-automated storage systems over lights-out automated warehouses?
In contemporary intralogistics procurement, businesses face an intensifying squeeze: industrial land costs and commercial lease rates continue to skyrocket, qualified forklift operators remain scarce and costly, and consumer demand surges for shorter fulfillment windows. While fully automated Automated Storage and Retrieval Systems (AS/RS) provide impressive speed, their extreme multimillion-dollar capital commitments, long multi-year construction cycles, and rigid inflexibility to changing SKU geometries frequently expose enterprises to severe financial and operational risk.
Semi-Automated Storage Solutions bridge this mission-critical gap. By pairing rugged, high-precision racking steelwork with intelligent, mechanized sub-systems—such as radio-controlled pallet shuttles, motorized mobile racking carriages, and vertical lift machines—facilities capture up to 80% more cubic storage density and 40% faster loading cycles. Lift-truck drivers no longer navigate deep, confined racking tunnels. Instead, pallets are delivered rapidly to the aisle face, eliminating structural collisions, improving operator ergonomics, and safeguarding company assets under stringent EN 15512 safety compliances.
Engineered precision: Watch how DEXION RACKING manufactures and commissions semi-automated high-density storage facilities worldwide.
Engineered to European FEM and EN structural tolerances, our semi-automated systems convert underutilized clear building height into hyper-dense, productive logistics assets.
Industry Standard An autonomous, battery-driven shuttle moves pallets along high-precision channel rails inside deep storage lanes. Forklifts transfer the shuttle between levels, while operators command load, retrieve, and inventory counting via a rugged Wi-Fi/RF tablet.
| Travel Speed | Up to 1.1 m/s (loaded) / 1.4 m/s (empty) |
|---|---|
| Battery Tech | Lithium Iron Phosphate (LiFePO4) 8h+ shift |
Max Footprint ROI Pallet racking blocks are mounted on electronically synchronized motorized wheel assemblies traveling along flush-mounted floor rails. Up to 9 conventional access aisles are condensed into a single dynamic opening, doubling storage capacity in the exact same footprint.
| Carriage Payload | Up to 800 Metric Tons per block |
|---|---|
| Safety Systems | Photocell light curtains & emergency stops |
Picking Velocity High-speed goods-to-person automated vertical storage machines optimize parts picking and inventory consolidation. Utilizing intelligent height sensors, trays dynamically compress stored materials, utilizing building ceiling clearance up to 15 meters.
| Footprint Saved | Up to 85% compared to static shelving |
|---|---|
| Throughput | Up to 300 order cycles per hour/unit |
Procurement in 2026 and beyond has moved past the simplistic question of "manual versus automated." Modern logistics engineering demands scalable adaptability.
Over the past decade, supply chain leaders witnessed multimillion-dollar rigid automation installations suffer severe throughput choke points when unexpected macroeconomic shifts, changing consumer packaging formats, or extreme SKU proliferation altered pallet configurations. Once an AS/RS stacker crane corridor is set, altering beam levels, pitch, or load profiles demands immense downtime and re-engineering expenses.
Forward-thinking procurement teams are establishing semi-automated infrastructure as a high-yield strategic baseline due to three emerging macro trends:
Future-proof logistics: DEXION RACKING high-density platforms allow frictionless retrofitting for AMR interfacing and cold-chain compliance.
From mechanical gravity-flow rollers to intelligent IoT-connected, sensor-fused shuttle vehicles.
The progression of semi-automated storage highlights dramatic improvements in mechatronics, power storage, and distributed industrial control systems:
| Generation & Architecture | Mechanical & Power Source | Operational Capability & Selectivity |
|---|---|---|
| 1st Gen: Gravity Flow & Push-Back | Mechanical incline roller tracks; brake wheels | High friction wear, restricted bay depth (<6 pallets), elevated pallet hang-up risks. |
| 2nd Gen: Lead-Acid Shuttles | Bulky lead-acid battery carriages; basic IR remotes | Heavy battery swap requirements, slow positioning speeds, limited diagnostics. |
| 3rd Gen: LiFePO4 Smart Shuttles | Lithium Iron Phosphate cells; ultrasonic distance sensors | Continuous 8-12h operation, rapid opportunity charging, automated SKU counts. |
| Current Gen: IoT & WMS Fusion | CAN-bus telemetry, optical encoders, mesh Wi-Fi | Predictive maintenance alerts, cold-store -30°C resilience, dynamic AMR handoff docks. |
Today, DEXION RACKING engineers integrate low-friction galvanized high-tensile guide channels, optical laser distance measurement units (ODS), and anti-collision sensor arrays directly into the structural steel profiles. The result is total positioning repeatability (±2 mm) under maximum rated loads, preventing product overhang, pallet snagging, and structural beam deformation.
Synchronized engineering: Unified structural racking, electronic controls, and high-density channels delivering continuous material flow.
Procuring storage infrastructure is an investment calculated over decades. Here is how DEXION RACKING delivers rock-solid reliability, certified structural safety, and verified technical execution.
All upright columns, baseplates, guide tracks, and load-bearing beams are engineered in accordance with rigorous European standards EN 15512, EN 15620, and EN 15635. We maintain exhaustive steel heat-batch traceability, guaranteed yield strengths, and ISO 9001 certified fabrication controls.
We do not outsource engineering integrity. From initial site slab survey, floor deflection analysis, and bespoke 3D CAD modeling to final factory acceptance tests (FAT), local site commissioning, and annual rack safety inspections, your operations team interfaces with one accountable partner.
Extreme sub-zero cold environments demand unique metallurgical properties and high-reliability mechatronics. DEXION RACKING shuttle drive motors, optical sensors, wiring looms, and high-density steel alloys are specially formulated to eliminate thermal fatigue and condensation short-circuits down to -30°C.
How DEXION RACKING eliminates deployment risks for global logistics managers and general contracting partners.
Engineers audit pallet profiles, weight distributions, floor slab load capacities, and building clearance envelopes.
Custom 3D CAD modeling, channel beam sizing, and finite element calculations strictly compliant with EN 15512.
Roll-forming of structural uprights, automated welding of mobile chassis, and stringent ISO 9001 quality audits.
Laser rail alignment, shuttle programming, safety light grid validation, and comprehensive forklift driver training.
Scheduled preventive maintenance, emergency parts dispatch, and certified annual safety compliance inspections.
By densifying your existing facility rather than constructing an expanded greenfield distribution center, you conserve thousands of tons of embodied concrete and steel emissions. In cold chain facilities, DEXION RACKING semi-automated solutions decrease refrigerated air volume waste by up to 50%, generating continuous double-digit kilowatt-hour utility savings year after year.
Critical answers to complex technical, budgetary, and structural questions frequently raised by international engineering and operations buyers.
Connect directly with our logistics application engineering team to receive a preliminary storage capacity calculation and custom layout scheme.
Case Highlight A regional fresh food distribution center deployed DEXION RACKING radio shuttles across 18 deep-lane channels, increasing pallet positions by 74% while reducing forklift travel cycles by 38%.
Turnkey Services From site floor laser profiling to full mechanical alignment, certified DEXION RACKING engineers guarantee on-schedule completion and compliant handover.