Cost-Effective Warehouse Automation for Smaller Projects
Warehouse automation is often associated with large facilities and complex systems. In reality, many operations need a more practical and cost-effective entry point. Smaller warehouses, regional distribution centers, and compact cold storage facilities face the same pressures around space, labor, and efficiency, but on a different scale.
Spacemaker Systems addresses this need with right-sized automation solutions designed for smaller projects, as well as cost-effective options for replacing existing pallet shuttle systems without a full rebuild.
Right-Sized Automation That Fits the Facility
Meaningful gains in storage density and throughput do not require oversized automation. When systems are properly matched to facility constraints and operational needs, even compact shuttle installations can deliver strong results.
In many smaller warehouses, selective racking is limited by height or layout, making depth the most effective way to increase capacity. Spacemaker shuttle systems enable deeper pallet storage within existing footprints, reducing forklift travel and improving material flow.
A small freezer installation supporting foodservice distribution for McDonald’s items is one example. Operating within a tight footprint and height-restricted environment, the facility used a right-sized shuttle system to increase pallet density and improve efficiency without overinvesting in automation.
Small Systems, Proven Impact
Smaller shuttle systems often deliver fast returns due to lower capital cost, reduced racking scope, and shorter installation timelines.
At a General Mills operation in Ohio, a compact shuttle system improved cold storage density by prioritizing depth over height while keeping the project aligned with budget expectations. In publishing distribution, Simon & Schuster deployed a small shuttle system supporting approximately 102 pallet positions, improving space efficiency and pallet handling without the complexity of a large automation rollout.
Similar benefits have been achieved in foodservice distribution environments such as Chick-fil-A, where compact shuttle installations streamline cold storage zones, reduce manual handling, and improve safety in space-constrained facilities.
These examples show that automation does not need to be large to be effective.
Cost-Effective Shuttle Replacement
Beyond new installations, shuttle replacement represents a strong opportunity for smaller projects. Many facilities continue to operate older pallet shuttle systems that are unreliable or no longer supported.
Spacemaker provides a practical replacement path that allows modern shuttle technology to be introduced while retaining existing racking where possible. This approach lowers project cost, minimizes disruption, and extends the life of the overall storage system, making it an efficient way to modernize smaller operations.
Practical Automation Without Overreach
Cost-effective automation is about applying the right level of technology to the right environment. Whether supporting a compact cold store, a regional distribution center, or a targeted shuttle replacement, Spacemaker enables operators to increase storage density, improve efficiency, and modernize operations without committing to oversized systems.
