Half-Pallet Automation: SMB Sets New Efficiency Standard in Beverage Logistics

Half pallets are inherently challenging to handle in intralogistics. The engineering team at German automation specialist SMB International have turned this challenge into a field-proven solution. Development of a storage system purpose-built for beverage handling in food retail began back in 2020, designed to handle both Euro pallets and half pallets with equal flexibility. The pallet shuttle system has since been rigorously tested and refined, and is now available as a turnkey warehouse solution, automating order assembly directly at the distribution center.

Beverage logistics in food retail has long faced a persistent challenge: while half pallets are ideal for in-store displays, transport, and digital tracking, order assembly at the warehouse remains demanding. The handling difficulties of half pallets are well known: reduced stability, higher error rates, increased handling time, and limited automation potential. With the new Truck Shuttle Half Pallet for Half Pallets, SMB International offers a purpose-built solution for the food and beverage industry that automatically handles store-ready pallets while streamlining operations, improving stability, and eliminating errors.

Why Half-Pallet Automation Is Key to Reliable Material Flow

For food retailers, a stable, uninterrupted supply to stores is the top priority. Beverage pallets in particular require precise, fast, and stable handling. Key challenges include:

• Half pallets are prone to tipping during transport
• Glass bottles and PET containers are sensitive to vibration
• Mixed orders combining Euro and half pallets add complexity

These factors lead to breakage, delays, returns, and costly rework. The Truck Shuttle for Half Pallets automates every step, handles all common pallet formats, and monitors each stage of the process.

End-to-End Intralogistics by SMB: Integrated Hardware and Software Expertise

The Truck Shuttle for Half Pallets is a carrier-satellite system comprising a transport vehicle (truck) and a pallet shuttle. An integrated turntable enables direct coupling and precise pallet alignment right on the load handling device.

An automated warehouse system equipped with these 2D truck shuttles handles both Euro and half pallets, automatically detects contour deviations or damaged skids, and diverts affected loads to an inspection area. This ensures optimal product protection while preparing transport-ready, store-specific pallets for dispatch.

The modules of the AS/RS automate all transport, rotation, and storage operations with precision and care. Store orders are sequentially staged for the automated vehicles through the modular Warehouse Management System (WMS/MFC). Warehouse staff interact solely through the control interface, which displays all orders in a clear, structured format.

How It Works in Retail Practice: Store-Ready Pallet Preparation

A retailer orders assorted beverages for multiple stores, including promotional items on half pallets and standard stock on Euro pallets. The Truck Shuttle for Half Pallets handles:

1. Load intake
2. Automatic alignment on the turntable
3. Store-specific order assembly
4. Storage and retrieval
5. Staging for dispatch

This delivers stable, transport-secure pallets ready for truck loading, with no manual rework, no unstable loads, no mis-shipments. Returns are minimized and loading times reduced.

Intelligent Automation for Transparency, Safety, and Efficiency

A key advantage of the shuttle system is end-to-end process reliability. Loads, pallet contours, and movements are continuously monitored. Gentle acceleration and braking keep loads stable, virtually eliminating breakage and rejects.

Parallel handling of Euro and half pallets ensures high flexibility for varying store requirements. The battery-free design reduces fire risk and enhances operational safety.

Key Benefits

• Multi-pallet capability: Parallel handling of Euro pallets, half pallets, and mixed loads
• Gentle product handling: Smooth motion profiles prevent tipping and breakage
• Efficient error management: Automatic detection and rejection of faulty pallets
• High operational safety: Battery-free operation minimizes fire risk
• Flexible software architecture: Modular design, adaptable to customer-specific requirements

Conclusion: SMB International Future-Proofs Beverage Logistics

Demands on food and beverage logistics continue to rise, especially for fragile or difficult-to-stack products. With the Truck Shuttle for Half Pallets, SMB International delivers the first fully automated solution for half-pallet order assembly, while processing Euro pallets in parallel.

More stable processes, less breakage, clear accountability, and significant efficiency gains at the warehouse.