The FD System: Dynamic Multi-Shuttle Case Handling AS/RS

Technology Overview

The Dematic FD System represents a significant evolution in automated case handling, built upon extensive expertise in case storage and picking. This Automated Storage and Retrieval System (AS/RS) is powered by Dematic's advanced, German-engineered multi-shuttle technology. It is designed to address the unique and demanding requirements of modern pallet-in/case-out or case-to-person operations. The system stands out for its ability to deliver superior performance across a wide spectrum of facility types, from sites with low clearance to towering high-bay warehouses exceeding 20 meters in height. By combining global technological innovation with localized adaptability, the FD System sets new benchmarks for flexibility, throughput, and storage density in industries ranging from grocery to pharmaceuticals.

How It Works

Core Principles

The core principle of the FD System is the use of a fleet of autonomous shuttle vehicles operating on multiple levels within a high-density storage racking structure. These shuttles dynamically store and retrieve cases, optimizing their movements in real-time to achieve the perfect balance between system throughput and operational cost.

Key Features & Capabilities

Advanced Multi-Shuttle Technology is the system's engine. This next-generation shuttle fleet is smarter and more adaptable, capable of handling diverse case sizes and weights up to 50kg, and operating efficiently in storage structures over 20 meters tall.

Architectural Flexibility allows the FD System to be tailored for both low-clearance facilities and ultra-high-bay warehouses. This means the core technology can be adapted to fit existing building constraints or designed into new, optimized facilities.

Dynamic System Optimization software constantly balances the workload across the shuttle fleet and storage locations. This ensures that the system delivers maximum throughput (up to 1,000 cases per hour) while minimizing energy use and equipment wear, aligning performance with cost-effectiveness.

Advantages & Benefits

The primary advantage is exceptional storage density and scalability. The system makes full use of available cubic air space, especially in high-bay configurations, allowing for massive inventory storage in a relatively small footprint, and can be expanded modularly.

It delivers consistently high throughput to meet demanding order cycles. The ability to handle up to 1,000 cases per hour ensures that distribution centers can keep pace with same-day or next-day delivery expectations.

The system provides unmatched adaptability for multi-industry use. Its design parameters (50kg payload, case handling) and software intelligence make it a singular solution capable of serving the distinct needs of grocery, e-commerce, apparel, 3PL, and pharmaceutical sectors within one technology platform.

Implementation Considerations

Implementing a high-bay FD System (20+ meters) requires specialized structural engineering and construction considerations, significantly impacting the project timeline and cost compared to lower-profile systems.

The success of the system hinges on seamless software integration. The dynamic optimization engine must be perfectly tuned to the specific operational workflows, product profiles, and order patterns of the business, requiring deep collaboration between the client and Dematic.

As a highly automated and mechanized solution, the total cost of ownership includes not only the initial capital expenditure but also ongoing maintenance for the shuttle fleet, lifts, and control systems, necessitating a clear long-term operational budget.

Use Cases & Applications

Ideal For

This system is ideal for large-scale distribution centers, wholesale B2B operations, and major third-party logistics (3PL) providers that require fast, accurate, and high-volume case picking from a deep reserve storage buffer to feed production lines, store replenishment, or e-commerce order assembly.

Performance Metrics

Key performance metrics from the content include a throughput capacity of up to 1,000 cases per hour, the ability to handle payloads up to 50 kilograms per case, and operation in storage heights exceeding 20 meters. These metrics directly contribute to outstanding storage density and scalability.

Conclusion

The Dematic FD System embodies the cutting edge of case-handling automation. By leveraging intelligent multi-shuttle technology within a flexible architectural framework, it solves the critical challenges of space utilization, speed, and adaptability in modern logistics. For businesses facing pressures from rising volumes, space constraints, or the need to serve multiple industry verticals with one system, the FD System offers a powerful, scalable, and efficient solution. Its implementation is a substantial undertaking that requires careful planning and partnership but promises to deliver a significant and sustainable competitive advantage through operational excellence and productivity growth.