The Double Reach Shuttle is an advanced automated storage and retrieval system (ASRS) designed to maximize space, improve efficiency, and meet the fast-paced demands of modern supply chains. 

Today, warehouses face growing challenges: rising order volumes, shrinking storage space, and increasing pressure to fulfill orders faster. As supply chains become more complex, businesses need smarter, more efficient solutions to manage inventory, streamline operations, and optimize space.

Muratec’s Double Reach Shuttle meets these demands head-on. This high-speed automated storage and retrieval system (ASRS) offers a compact, high-density storage solution that enhances efficiency, boosts throughput, and enables seamless Goods-to-Person (GTP) picking. By maximizing storage capacity within a reduced footprint, it improves order accuracy, accelerates fulfillment, and helps businesses adapt to the evolving demands of e-commerce, retail, and distribution.

Engineered for speed and precision, the Double Reach Shuttle combines a space-saving design, high-speed throughput, and versatile functionality. It provides warehouses and distribution centers with a powerful tool to streamline operations, improve accuracy, and meet the growing demands of a fast-paced supply chain.

This innovative system integrates compact design with high storage capacity, making it ideal for facilities seeking to maximize efficiency while accommodating a growing number of SKUs. Equipped with a narrow shuttle that carries a single load and a unique double-reach transfer mechanism, the system minimizes aisle width requirements, optimizing storage space. A high-speed shuttle and vertical conveyor enable rapid throughput and efficient Goods-to-Person (G2P) picking.

The double-reach transfer mechanism allows the shuttle to retrieve loads stored at greater depths, moving them back and forth within storage racks. This design maximizes storage capacity and ensures rapid product access, enhancing order fulfillment speed to meet growing customer demand for faster deliveries.

The Double Reach Shuttle’s goods-to-person picking functionality reduces manual retrieval time, boosting efficiency and accuracy across receiving, replenishment, picking, packing, and shipping operations. Automating these tasks increases throughput, ensures consistent order accuracy, and speeds up response times, which are crucial in retail, wholesale, and distribution.

Muratec’s Double Reach Shuttle ASRS supports multiple warehouse tasks, consolidates processes within a compact footprint, and provides flexible handling options for pallets, cases, and split-case items.

“It is unique compared with competitors’ systems due to its narrow vehicle size and free-sized case handling,” said Masatoshi Wakabayashi, general manager of Muratec’s Logistics & Automation division.

A Closer Look: Key Features and Benefits

Space Optimization

The Double Reach Shuttle’s narrow shuttle and unique double-reach transfer mechanism minimize aisle width, significantly reducing the storage area footprint while doubling storage volume.

High-density storage accommodates the growing number of SKUs in facilities with limited space.

High Speed and Throughput

The system operates at speeds of up to 787 feet per minute (240 meters) for single-deep configurations and 590 feet per minute (180 meters) for double-deep configurations.

It can handle approximately 1,000 cases per hour per aisle for combined inbound and outbound operations, making it ideal for fast-paced environments.

Versatile Applications

Designed for handling cases and lightweight loads, the system supports a wide range of tasks, including:

• Receiving
• Tracking
• Replenishment
• Picking
• Packing
• Assembly/Kitting
• Sorting
• Shipping
• Inventory Management

It accommodates diverse load sizes, not just containers or bins of a specific size.

Efficiency Gains

• Automates manual processes, enhancing order accuracy and throughput while reducing retrieval time.
• High-speed operations improve fulfillment speeds and enable rapid Goods-to-Person (G2P) picking.
• Proven to boost efficiency and productivity in retail, wholesale, e-commerce, and distribution.

Innovative Design

• A modular, scalable structure allows easy customization and expansion based on operational needs.
• Handles load sizes ranging from 6.9-25.6 inches (175–650mm) in width, 7.9-25.6 inches (200–650 mm) in depth, and 3.5–23.6 inches (90–600 mm) in height.
• Weight capacity ranges from 2.2 to 66.1 pounds (1 to 30 kilograms).

Addressing Supply Chain Challenges

The Double Reach Shuttle ASRS helps businesses meet customer demands for faster response times. By automating key processes like replenishment, picking, and inventory management, it significantly reduces the time and labor required for traditional warehouse operations.

Applications and Industries

This system is particularly suited for:

• E-commerce: Supporting high SKU diversity and rapid order fulfillment.
• Retail and wholesale: Streamlining replenishment, picking, and inventory control.
• Manufacturing: Facilitating kitting, sorting, and just-in-time assembly processes.
• Distribution centers: Maximizing space utilization and throughput in high-volume operations.

See the Double Reach Shuttle in motion at ProMat 2025 in Chicago, Booth 1231.

“Industries like retail and e-commerce require high-speed and high-volume sortation of high SKUs and mixed case sizes,” Wakabayashi said. “The Double Reach Shuttle will answer these demands well. By combining the Double Reach Shuttle with a loop sortation system (such as the Muratec Shuttliner, a high-performance case transport system and vehicles equipped with conveyors that travels in a loop layout), a warehouse will be able to achieve high-speed, high-density sortation and sequencing with a minimal footprint compared to conventional solutions with sortation conveyors.”

A Hybrid Solution

While primarily a mini-load system for handling cases and split-case items, the Double Reach Shuttle can also serve unit-load applications. Its flexibility to manage both smaller and larger loads makes it an adaptable solution for facilities dealing with a mix of product types and sizes.

Mini-Load Features

• Designed for high storage density with a narrow shuttle and double-reach mechanism, ideal for handling smaller items like cases and split-case goods.
• Focuses on Goods-to-Person (G2P) picking and fast throughput, aligning well with mini-load system characteristics.

Unit-Load Capabilities

• Capable of handling pallets, a defining feature of unit-load systems.
• Manages larger and heavier loads when required, broadening its applicability beyond traditional mini-load operations.

Muratec embraces the philosophy of empowering automation to handle repetitive tasks, allowing people to focus on the skilled, strategic work that only humans can do. The Double Reach Shuttle exemplifies this innovation, Wakabayashi said.

“With emerging demands for picking, retrieval, and sortation of high SKUs in large distribution centers for e-commerce, wholesale, and retail businesses that require extensive manpower, the Muratec Double Reach Shuttle plays a key role. Its high-density, high-speed storage and retrieval system for free-case handling, along with other continuous innovations from Muratec logistics solutions, require less manual labor and significantly reduce workers’ walking distance,” Wakabayashi said.

See It in Action

The Double Reach Shuttle ASRS is the newest addition to Muratec’s automated storage solutions for small products and storage retrieval. Experience its compact efficiency at ProMat 2025, Booth S1231.