Efficient warehouse management is key for any company that handles large volumes of goods. In this context, different types of stacker cranes have become an indispensable solution for optimizing space utilization, improving operating speed, and reducing logistics costs.
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These automated systems enable precise and safe product handling, adapting to a variety of business needs. That is why it is important to learn about the different types of stacker cranes, their applications, and the key factors you should consider when choosing the right one for your business.
What is a stacker crane and how does it work?
Stacker cranes are automated systems designed to move, deposit, and retrieve goods from high-rise racks in industrial warehouses. They operate using a vertical and horizontal movement mechanism, which allows products to be accessed efficiently without the need for direct human intervention.
These devices are equipped with a system of guides, sensors, and software that optimize their operation, reducing errors and maximizing the performance of the available space. In addition, their ability to integrate with other logistics technologies makes them an ideal choice for companies looking to improve inventory management and streamline internal processes.
Types of stacker cranes and their applications
Depending on the type of load unit and the level of automation required, stacker cranes can be classified into several categories. Each offers specific benefits in terms of speed, capacity, and adaptability to different industrial environments. Among the main types of stacker cranes available are:
1. Pallet stacker cranes
Pallet stacker cranes are specifically designed to handle large loads in distribution warehouses, where space optimization and efficient goods handling are essential. Their structure allows vertical storage on high racks, facilitating automatic access to products without the need for manual intervention. Thanks to their high load capacity, these systems are ideal for industries that handle heavy or bulky materials.
Logistics, manufacturing, and retail companies find these stacker cranes to be an effective solution for inventory management, as they allow for quick product retrieval and improve workflow within the warehouse. The automation they offer significantly reduces errors in goods handling and ensures efficient stock management, optimizing operating costs and increasing productivity.
2. Box stacker cranes
This type of stacker crane specializes in handling smaller and lighter loads, offering an efficient solution for warehouses that work with high-turnover products that need to be moved from one place to another more frequently. Box stacker cranes are particularly useful in sectors such as e-commerce and the pharmaceutical industry, where fast access to products is essential to ensure operational efficiency.
One of their main advantages is their ability to integrate with picking systems, enabling fast and accurate product retrieval. In addition, by optimizing internal warehouse space, box stacker cranes contribute to better inventory organization, minimizing internal logistics errors and improving the customer experience in terms of delivery times and product availability.
3. Light load systems
Light load systems are designed for environments where lighter, more compact products are handled. They are widely used in industries such as electronics and fashion, where automation of the storage process is key to reducing handling times and improving operational efficiency. These systems allow for high storage density without compromising product access speed.
In addition, light load stacker cranes can be easily integrated with advanced warehouse management technologies, optimizing workflows within the warehouse. Their flexible structure allows them to adapt to different storage configurations to transport products efficiently, making them a versatile option for companies looking to improve logistics without increasing physical storage space.
4. Key differences and applications in different sectors
Each type of stacker crane fulfills a specific function in product storage, so it is important to consider their differences and applications. Pallet stacker cranes are the best option for companies that handle large volumes of cargo and need to maximize vertical storage space. They are more robust and suitable for heavy or bulky products, ideal for industrial and distribution sectors.
On the other hand, light-duty systems and box stacker cranes are more dynamic solutions for companies that require quick access to smaller products. In industries with high turnover, such as fashion, electronics, and e-commerce, these systems ensure efficient inventory management and optimize operating time without sacrificing stock control.
Factors to consider when choosing the right stacker crane
Given that there are different types of stacker cranes, each with specific characteristics, you may be wondering: How do I know which one is best for my company? The truth is that there are a number of important factors to consider before making a decision, and we will discuss them below:
1. Load capacity and volume
Load capacity is one of the most important aspects when choosing a stacker crane. If the company handles heavy or large-volume goods, it will be essential to choose a heavy-duty system that guarantees stability and safety in storage. A stacker crane with a robust structure will not only allow for better weight distribution on the racks, but will also optimize the loading and unloading of products without compromising their integrity.
In addition, load volume influences warehouse operating dynamics. A system designed to handle large quantities of goods will improve operating times by reducing the need for unnecessary movements. In contrast, warehouses with smaller loads can benefit from more compact models that allow for efficient product retrieval without sacrificing storage capacity.
2. Type of goods stored
The type of goods handled within the warehouse also plays a decisive role in selecting the right stacker crane. In sectors such as the pharmaceutical or electronics industries, where products require special storage and handling conditions, it is necessary to have adapted technology that guarantees precision and safety. An error in the handling of these products can lead to economic losses or quality problems that affect operations.
On the other hand, more standard loads, such as retail or manufacturing items, can use storage systems with a more generalized approach. In these cases, stacker cranes that prioritize access speed and space optimization will be the best option, as they will allow the process to remain agile without requiring specific technical adjustments.
3. Warehouse dimensions
Warehouse dimensions largely determine which type of stacker crane is most suitable. In small spaces, it is essential to have compact systems that maximize the use of available area without affecting workflow. This means that rack layout and storage height must be evaluated before making a decision, ensuring that the chosen solution fits the existing infrastructure and does not create narrow aisles that hinder movement.
In larger warehouses, high-capacity stacker cranes offer a competitive advantage by enabling better product segmentation and efficient inventory distribution. Choosing a system with greater reach and handling capacity optimizes overall warehouse performance, reducing operating costs and improving internal logistics.
4. Required level of automation
The level of automation required by the company is also a key aspect to consider. Companies looking to reduce errors and improve operational efficiency can benefit from fully automated stacker cranes, which enable precise inventory management without manual intervention. This type of solution is ideal for warehouses with high turnover volumes, where speed and stock control are essential.
In addition, efficient management software will improve overall warehouse performance by optimizing product traceability and reducing the possibility of losses or errors. Integration with planning and monitoring systems facilitates inventory management, ensuring that every movement of goods is correctly recorded and aligned with the company’s operational needs.
Benefits of implementing a stacker crane in your company
Without a doubt, incorporating stacker cranes into your business’s storage infrastructure provides multiple benefits in terms of efficiency and operating costs. Among the most notable are:
- Space optimization:
- They allow for better use of warehouse height, maximizing storage capacity.
- They reduce the need for physical expansion of space.
- Reduced operating times:
- They streamline the product retrieval process, improving dispatch speed.
- They eliminate delays caused by manual handling.
- Minimization of inventory management errors:
- They ensure accurate and automated stock management.
- They reduce losses and minimize the margin of error in internal logistics.
Conclusion
Integrating different types of stacker cranes into your company’s storage system is a strategic investment that guarantees efficiency, safety, and operational optimization. Each type of stacker crane is designed for specific needs, so evaluating factors such as capacity, load type, and level of automation is key to making the right choice. If you need this type of storage system, don’t hesitate to check out what we have available for you.
The market offers different types of stacker cranes to meet the needs and attributes of each warehouse: from installations ranging from 8 to 45 metres tall to those with different unit loads (boxes and pallets) and extremely varied movement flows.
Likewise, the stacker crane extraction system can be adapted to operate with single-, double-, and triple-deep racks, based on whether the goal is more agility or increased storage capacity.
In this post, we delve into the different kinds of stacker cranes installed in automated warehouses and their particular characteristics, advising you on the model that best fits your needs.
Types of stacker cranes for boxes and pallets
There are several varieties of stacker cranes available according to the goods to be handled: stacker cranes for pallets and those that work with lighter unit loads ─e.g., boxes─, also known as miniload. The main difference between them lies in the size of the stacker crane and the weight supported, as stacker cranes for pallets are much larger and robust than those for boxes.
In addition to the goods they handle, each type of stacker crane can be classified by its structure and, more specifically, the number of masts. The mast is the body of the stacker crane. It incorporates what’s known as the cradle, which comprises forks that support the unit load. Depending on the load dimensions or the desired operating speed, the stacker crane will be formed by one mast (single-mast) or by two (twin-mast).
The stacker crane moves along a bottom rail attached to the concrete floor slab and an upper guide rail fixed to the rack profiles. These are charged with stabilising the stacker crane and absorbing lateral forces when inserting and removing goods from the racks.
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All stacker cranes can operate 24/7 in temperatures as low as -30 °C. In order to operate in both cold storage and ambient temperature facilities, stacker cranes are equipped with a warehouse control system (WCS) that executes the movements indicated by the warehouse management system (WMS).
Single-mast stacker cranes
Available for both boxes and pallets, these machines are made up of a single mast and are designed to provide the utmost functionality and efficiency in installations with lighter loads.
With regard to single-mast stacker cranes for pallets, Mecalux features up to five models. These range from the MT-1 model for shorter installations to the MT-5 model, capable of reaching 45 metres high.
The height of the stacker cranes is conditioned by the weight of the unit load, that is, the taller the stacker crane, the lighter the weight of the pallet. Therefore, the ideal pallet weight for these types of stacker cranes is between 1,000 and 1,500 kg. The wide array of models makes it possible to choose the most appropriate stacker crane for the available space and the goods to be handled.
FEATURES
MT-1
MT-2
MT-3
MT-4
MT-5
Max. height – single-deep
18 m
24 m
33 m
36 m
45 m
Max. height – double-deep
15.5 m
22 m
27 m
33 m
45 m
Single-deep telescopic fork
Yes
Double/triple-deep telescopic fork
Optional
Automated Pallet Shuttle
Optional
Max. permitted load – single-deep
1,500 kg
1,500 kg
1,500 kg
1,000 kg
1,000 kg
Max. permitted load – double-deep
1,000 kg
1,000 kg
1,000 kg
1,000 kg
1,000 kg
Max. travel speed
220 m/min
Max. travel acceleration
0.5 m/s
Max lift speed
66 m/min
Max. lift acceleration
0.6 m/s
Side-mounted cabin
Optional
Operations temperature range
From -30 °C to +40 °C
Max. load dimensions
1,000 x 1,300 x 2,400 mm
Pallet type
Europallet 800 mm and 1,000 mm wide (EN-)
Energy recovery system
Optional
In terms of boxes, we offer two varieties of single-mast stacker cranes. The ML-50 is lighter and devised to achieve high productivity when handling 50 kg boxes at heights of 12 m. The other intermediate variety (ML-100) is sturdier and can load two boxes, each weighing 50 kg, at 12 m.
FEATURES
ML-50
ML-100
Load capacity
Up to 50 kg
Up to 100 kg
Max. height
12 m
12 m
Unit load
Eurobox, 1 unit: 400 x 600 mm
Eurobox, 1 unit: 600 x 800 mm / 2 units: 400 x 600 mm
Double-deep telescopic forks
Yes
Yes
Twin-load extraction fork
No
Yes
Max. travel speed
180 m/min
200 m/min
Max. travel acceleration
1 m/s
0,7 m/s
Max. lift speed
100 m/min
90 m/min
Max. lift acceleration
1.2 m/s
0.75 m/s
Extraction type
Telescopic fork
Adaptable to box type
Twin-mast stacker cranes
Their structure consists of two vertical masts with a lifting cradle in the middle that’s used to access all the storage levels. These types of stacker cranes are more resistant and robust than the twin-mast variety, which makes them perfect for handling heavy loads. They also enable high throughput due to their to agility.
The pallet variety of these stacker cranes is ideal for handling pallets weighing up to 1,500 kg. In accordance with the required height, Mecalux has seven available models of twin-mast MTB stacker cranes. The MTB0 stacker crane has been added to this family. It’s a more affordable, energy-efficient model that handles 1,500 kg pallets but at a limited height: 18 metres.
FEATURES
MTB-1
MTB-2
MTB-3
MTB-4
MTB-5
MTB-6
MTB-7
Max. height – single-deep
12 m
17 m
22 m
27 m
35 m
40 m
45 m
Max. height – double-deep
-
12 m
20 m
27 m
35 m
40 m
45 m
Single-deep telescopic fork
Yes
Double/triple-deep telescopic fork
Optional
Max. permitted load
1,500 kg
Max. travel speed
220 m/min
Max. travel acceleration
0.5 m/s
Max. lift speed
66 m/min
Max. lift acceleration
0.8 m/s
Automated Pallet Shuttle
Optional
Optional raisable maintenance cabin or onboard static cabin
Yes
Operation temperature range
From -30 °C to +40 °C
Max. load dimensions
1,100 x 1,300 x 2,400 mm
Pallet type
Europallet 800 mm and 1,000 mm wide (EN-)
Energy recovery system
Optional
For their part, twin-mast stacker cranes for boxes can reach heights of 20 metres and handle up to four boxes, each weighing 50 kg.
Double-deep twin telescopic forks
FEATURES
MLB100Q-2EPSF
MLB100Q-2EPDF
MLB100Q-2ECDF
Max. height
12.29 m
12.29 m
12.29 m
Min. height
5.04 m
5.04 m
5.04 m
Type of extraction system
Single-deep twin telescopic forks
Double-deep twin telescopic forks
Double-deep twin telescopic forks with belt
Max. permitted load
2 x 50 kg / 2 x 100 kg
2 x 50 kg
2 x (50 + 50) kg
Box/container size
400 x 600 / 600 x 800 mm
400 x 600 mm
400 x 600 mm
Max. travel speed
250 m/min
250 m/min
250 m/min
Max travel acceleration
1.45 m/s
1.45 m/s
1.8 m/s
Max. lift speed
90 m/min
90 m/min
90 m/min
Max. lift acceleration
1.5 m/s
1.5 m/s
1.5 m/s
Twin-mast stacker cranes with Pallet Shuttle
This combination of a stacker crane with the Pallet Shuttle system is only applicable to palletised goods. It is the evolution of the twin-mast stacker crane described above, the difference being that it incorporates a motorised shuttle tasked with extracting and depositing the pallets from and on the racks. The shuttle can enter channels up to 40 m deep.
It’s a widely-used solution for maximising storage capacity. This optimisation of space involves less accessibility to the goods, so it’s especially advantageous for companies with diverse low-to-medium-turnover SKUs. On the other hand, it’s a very handy option for automated cold stores, as it results in major savings in energy consumption.
Trilateral stacker cranes
As opposed to those above, trilateral stacker cranes have the ability to retrieve and deposit pallets from/in the racks in three positions — from the front and either side — thanks to their rotating head. In contrast, single-mast and twin-mast stacker cranes can only operate in two positions, preventing them, for example, from leaving pallets on consoles located at the ends of the racks or to pick pallets from the ground level in the front position.
Trilateral stacker cranes are the go-to solution for warehouses already working with manual trilateral turret trucks and that want to automate processes without interrupting operations. Why? They are very simple to install: they also move along rails, but, unlike other stacker cranes, they don’t require an upper guide rail. (That is, there is no fastening device at the top of the stacker crane). This allows for easier installation in warehouses that already have racking set up, without having to modify the building structure.
A case study illustrating this type of facility is that of Disalfarm at its warehouse in Rubí (Barcelona, Spain). This leader in the pharmaceutical distribution sector transformed 15 aisles of pallet racks managed with manual forklifts into a fully automated installation operated by means of trilateral stacker cranes What’s most remarkable about this project is that our company optimised the warehouse without requiring the company to stop its activity at any time.
Types of extraction systems
Within the configuration of each type of stacker crane, you can choose the type of extraction system that best fits the unit-load depth (number of pallets deep) of the racks. It should be noted that the cradles of the stacker cranes can be customised to be able to handle several unit loads simultaneously (one on each side).
The extraction system is a decisive element for the performance of the stacker cranes. The choice of extraction system is directly related to the agility and/or storage capacity required by each warehouse. In other words, the fewer the unit-loads deep, the greater the flexibility in movements; meanwhile, the more positions in depth, the higher the capacity and the lower the performance.
Extraction systems for pallets generally comprise telescopic forks made up of two arms joined together by a motor-driven drive shaft. One motor is installed when working with single-deep racks, while two motors are used in the case of double-deep racks.
The extraction system of stacker cranes for boxes, in turn, consists of telescopic forks composed of two sliding structures. It’s also very common to employ a motorised belt fork, operated by a dual-belt system that pulls the box.
Single-deep system
The single-deep system is a mechanism that makes it possible to extract load units from single-deep racks.
This type of extraction system provides the highest throughput, as, when loading a single unit load, agility in handling takes priority over storage capacity. This is also the most recommended system for working with very heavy loads.
Double-deep system
With the help of telescopic forks, it’s possible to extract or deposit pallets or boxes in double-deep racks. This way, you achieve a balance between agility and storage capacity.
It’s a common solution for optimising storage space when you don’t require high movement flows and work with few SKUs.
Triple- or quadruple-deep
This extraction system works with racks that are three or four unit-loads deep. This exceptional solution is only implemented when there’s a very specific need and the warehouse prioritises capacity over agility.
This is the case of the WOK facility in Poland, where our company outfitted two 86.3 long aisles with four-pallet-deep racks on each level. Two twin-mast stacker cranes are tasked with handling up to four pallets weighing no more than 600 kg.
Motorised roller conveyor platform
This extraction system is used to feed live pallet racking composed of rollers and with several positions deep. It ensures high loading and unloading speeds, since movements are continuous and synchronised.
This is the system installed at the Laboratorios Maverick warehouse in Tarragona, Spain, where a single-mast stacker crane with an onboard roller conveyor inserts pallets in flow channels This facilitates the gravity displacement of the load from the highest to the lowest part of the channel.
Which stacker crane do I need?
Choosing the right stacker crane for your warehouse is no easy task. There’s no rule of thumb, as each installation has its own quirks. Likewise, the different varieties of stacker cranes can be modified to provide a more personalised solution.
With this in mind, first, you need to be absolutely certain of your company’s needs and goals, the type of product to be stored (quantity, size, weight, number of SKUs, etc.), the type of material flows required, the warehouse layout, and your budget.
Then, we’ll be able to analyse the movements the different types of stacker cranes are able to execute, always according to the extraction system used. This will depend on:
- Travel speed
- Lift speed
- Accelerations at any axis
- The time needed to remove or deposit the unit load
Out of all the options, it’s important to assess which one will give you the most functional and cost-effective features, always striving to strike a balance.
Of course, the various types of stacker cranes can be adjusted and adapted to the demands of each warehouse. However, both the height and type of extraction system are conditioned by, among other factors, the depth and dimensions of the racks.
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