FERRETTO
GUIDE
FLEXY
THE SHUTTLE SETTING
THE WAREHOUSE IN MOTION
SPEED, PRECISION
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AND SAFETY
The efficient handling of goods
is a key factor for the successful
operations of a warehouse.
Thanks to the development of automation, companies
today can count on state-of-the-art solutions able to
improve speed, precision, safety and efficiency.
The Flexy automated pallet shuttle is the system
designed by Ferretto Group for diverse warehouse
solutions, ideal for high-density storage systems with a
large number of items. It represents the evolution of the
push-back racking unit.
What is a shuttle?
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A shuttle is a small automation for the
handling of pallets on multi-depth storage
(also known as compact system).
A compact system ensures a better use of space
allowing the access only to the first pallet of each lane; it
is used when for the same SKU there are a large number
of pallets: each lane must have therefore a single SKU.
The shuttle allows the access to the unit loads inside
each lane. It is used in both automatic and traditional
multi-depth storage solutions.
The shuttle operations can be controlled by the operator
(typically the forklift driver) via remote control or
interfaced to a WMS (Warehouse Management
Systems) application.
How it works
The shuttle lifts up the unit load and moves it along the lane until it reaches the first free position. Then,
it comes back to the beginning of the lane ready for the next drive cycle.
It is thus possible to store a large number of pallets in depth on each single lane, thereby optimizing
the storage density.
A shuttle system overtakes the storage limits of the drive-in / drive-through racking solutions, where
the same SKU must be placed on every lane of each channel. On the contrary, a shuttle system requires
the same SKU only inside the same lane.
Thanks to its versatility, the pallet shuttle system can work either as First in, First out (FIFO) or as Last
in, First out (LIFO).
FLEXY
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AUTOMATIC SHUTTLE
Flexy is the shuttle for pallets This storage system can be integrated with the company
conceived by Ferretto Group for ERP via the WMS, thus taking advantage of Industry 4.0
technologies and methods.
the most different warehouse
applications. Finally, the shuttle guarantees high performance both at
room temperature and in cold rooms with temperatures of
It is a highly flexible solution, as it up to -30°C.
can be used with different types of
pallets. Flexy has been designed with
8 wheels to ensure a greater traction
and a better load distribution on the
lane guides.
Powered by a rechargeable lithium
battery, Flexy offers up to 8 hours of
work at full capacity.
All these features optimize storage
operations, increasing efficiency and
performance while reducing workpla-
ce accident rates both to personnel
and goods.
Further shuttle carts can also be
added to the racking structure over
the time to enhance productivity.
Advantages
• High density storage system allowing • Faster handling operations
to manage different SKUs in the
same channel • Greater operating efficiency
• Operating temperature between • Space optimization
-30°C to +35°C
• Reduced risk of accidents
• Suitable for different pallet sizes (compared to drive-in solutions)
• Scalable simply increasing the • Low risk of damage to racks
number of shuttles and goods
• Lower operating costs • Low maintenance costs
FLEXIBILITY
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SERVING YOUR WAREHOUSE
The versatility of Flexy shuttle is the perfect answer to any storage need.
1
Storing pallets using Flexy shuttle
How does Flexy actually work?
Let’s see what happens inside a warehouse:
1 The forklift truck places the shuttle on the lane of the
channel to be loaded. The forklift truck places a pallet on the
lane front.
2 A single command remotely entered by the operator allows the
shuttle to carry and store the pallet inside the racking system. 2
No further operator’s activities are required.
3 Flexy places the unit load in the first free position available in
the lane. Once the operation has been completed, the shuttle
automatically returns to the beginning of the lane to collect
the next unit load.
4 Before placing the last pallet on the lane so to fill it up, the
forklift truck removes the shuttle and shifts it to another lane.
What about the operators? 3
While Flexy shuttle moves a unit load along the lane, the
operator can focus on the next pallet to be stored, optimizing
handling times within the warehouse. As a result, storing
operations are carried out more efficiently, granting as well higher
performances and safety both to goods and operators.
Flexy is suitable for many types of goods:
• Fast-moving consumer goods
• Highly perishable products
• Goods produced in batches
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Some figures The number of Flexy shuttles
required depends on:
Flexy has a nominal capacity of 1500 kg • Number of pallets to be handled per hour
and a translation speed ranging from 0.65 • Length of channels, number of lanes and
m/s at full load to 1.1 m/s when empty. layout of the warehouse
The lifting time is 3 seconds.
• Timing required for moving the pallet with
The shuttle is available in three models, the forklift from the collection point to the
suitable for pallets with depths from 800 lane and vice versa
mm up to 1200 mm. Flexy also allows to
manage pallets with goods protrusion. • Number of forklifts working at the same time
Flexy drien by WMS
(Warehouse Management System)
WMS developed in-house by Ferretto
Group enables Flexy to communicate
directly with the company’s ERP system.
Commands are conveyed via WIFI, thus
fully integrating Flexy in the warehouse
management.
As a result, storing operations are
carried out more efficiently, picking
errors are reduced to zero and the
utmost safety is ensured both for
goods stored and operators involved.
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A safe automation for the warehouse
Flexy operating safety is ensured by different devices.
Among them :
• Emergency stop, activated when pressing the specific button
on the shuttle.
• Electromechanical “bumpers”, to prevent the shuttle from
impacts during operation.
• Light and sound alarms, to signal the operations in progress
and the direction.
• Control sensors, to detect any wrong position of the Flexy shuttle.
1
8
9 13
Main 4
components 5
15
6
1 Lifting gearmotor 10
7
2 Translation gearmotor
11
3
3 Wi-fi/Radio antenna 12 2
4 On/Off button 14
Alarm/Emergency reset button
5 Emergency push-button
6 Electromechanical bumper
11 Idle wheels
7 Laser distance sensor
12 Drive wheels
8 Inductive sensor to detect the
presence of the Flexy shuttle 13 Lithium battery
9 Lift shaft 14 Flexy shuttle stop sensor
10 Drive chain 15 Lifting position sensors
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A smart operating tool
The use of Flexy shuttle positively affects the way the operator works.
Thanks to the wireless control unit, all operations can in fact be managed safely and accurately. In
addition, the operator can monitor all parameters and information about the status of the shuttle in
real time.
Through a simple and intuitive keyboard, the operator can set the various controls: select manual
or automatic mode, select automatic loading and unloading cycles of the ULs both in individual or
continuous mode, run diagnostics, and set the UL positioning distance parameters. Alternatively,
the shuttle can be managed by the WMS, connected to the company’s ERP system: in this case, the
operator receives instructions through the terminal controlled via Wi-Fi, in accordance with Industry
4.0 processes.
A complete control
From the radio control unit menu, the operator can monitor all parameters such as the total cycles
performed by the selected shuttle or the number of pallets stored in a given channel.
Among the available functions is it possible to find:
• Counting function to count the number of pallets already stored Different cycles
in a lane. The cycle consists of a run from back and forth from
the beginning to the end of the lane. for different needs
• Continuous loading cycles function for a faster filling of a Depending on the needs, the
lane: no additional commands are needed to start the next operator can set different
positioning cycle. cycles:
• Special continuous unloading cycle function used for a • Single load
massive unloading of a lane: no additional commands are single pallet storage
needed to start the next retrieving cycle command
• Continuous load
continuous pallet
On storage command
Off
Power On / Off (massive loading)
• Single unload
command to retrieve
Manual / Automatic the first pallet available
Man
Unload
• Continuous unload
Load Auto lane emptying command
(massive unloading)
Compact Continuous unload
Up • Special continuous
Manual controls / unload
Back Forw
Browsing menu special continuous lane
Down
emptying command
Select shuttle 1 2 3 4 • Compaction
pallet reordering
command for FIFO
Quick stop /
System menu Menu STOP storage logic
Reset
TELESERVICE
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ONLINE ASSISTANCE SERVICE
Ferretto Group supports
its customers also with the
after sales assistance.
Through the remote assistance software
and special devices integrated on the
shuttle, the after sales support team can
remotely connect to the automation and
detect any possible failure in real time,
while remaining in direct contact with the
customer.
Remote assistance therefore detects any
possible failure in the system and provides
warehouse operators with the necessary
instructions to restore the data.
Remote monitoring also allows to acquire
system data such as cycle timing, battery
charge, efficiency and thus monitor the
performance of the system over time.
LEARN MORE ABOUT
FLEXY
For more information about Flexy,
go to the relevant section of our website or contact us.
Strada Padana verso Verona, 101
36100 Vicenza, Italia
Tel. +39 0444 349688 - Fax +39 0444.349498
info@[Link]
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