May 11, 2026
Pallets Precisely Positioned
In automated pallet shuttle warehouses, the position of each machine must be tracked in real time. Italian solution provider Eurofork relies on a powerful positioning system from Pepperl+Fuchs for its pallet shuttle.
Italy is not only the birthplace of pizza, pasta, and espresso, but also home to a strong economy. In Turin, the capital of the Piedmont region, magnificent Baroque squares and arcades spread out against the picturesque backdrop of the Alps. Eurofork is located near the city, which has been named the European Capital of Innovation in 2024.
With over 130,000 systems sold in more than 95 countries, Eurofork is a globally recognized solution provider in the field of intralogistics. From telescopic forks for automated storage and retrieval systems to innovative pallet shuttles, the company offers a complete range of automatic handling solutions equipped with state-of-the-art sensor technology. This includes the E4SHUTTLE, a system for intelligent pallet handling in automated warehouses.
Flexible on the Go
In such warehouses, pallet shuttles travel autonomously along aisles and storage channels within the racking system. These automated handling solutions store and retrieve pallets, ensuring an efficient inbound and outbound flow of loads. The storage systems offer high throughput and flexibility: depending on requirements, the number of vehicles can be increased or reduced during operation. Multiple shuttles can also operate simultaneously on the same level. Such systems are especially suitable for companies requiring high-density storage with multi-depth, multi-SKU, and multi-level configurations.
Automated storage and retrieval systems (AS/RS) with multi-depth pallet storage present a specific challenge. In these systems, several pallets are stored one behind another in a storage channel, which complicates storage and retrieval operation. To address this type of warehouse environment, Eurofork has developed the E4SHUTTLE. This four-way pallet shuttle can operate autonomously along both the X- and Z-axes of the warehouse. With the help of a lifter, it can also change warehouse levels (Y-axis) according to any requirement of the software.
This capability enables the shuttle to move directly into storage channels and reach any pallet position without requiring additional equipment. “As a result, the system offers exceptional flexibility and can adapt effectively to various warehouse types, including those with complex layouts,” explains Alessandro Garola, Chief Technology Officer at Eurofork.
Real-Time Positioning
To ensure smooth and efficient storage and retrieval, the positions of the shuttles and pallets must be tracked at all times. To do this, Eurofork relies on the PCV Data Matrix system from Pepperl+Fuchs: an absolute positioning system enabling detailed 3-D mapping of the entire warehouse. “The technology is very easy to use,” says Garola. “The PCV read heads are installed on the E4SHUTTLE. These read the Data Matrix codes, which are attached as code tapes throughout the warehouse: in all main aisles and lanes, and vertically along the lifts. Since the shuttle always knows its exact position, each pallet's location is inherently defined by the shuttle’s position when storing or retrieving it.
The E4SHUTTLE navigates precisely by reading the PCV code tapes throughout the warehouse.
Installed on the shuttle, the PCV read head reliably reads the Data Matrix codes.
Compared to 1-D coding, Data Matrix coding offers a significantly higher data storage capacity. This makes position determination highly reliable. The codes are redundant, ensuring that they can still be read even if the code tape is bent, dirty, or partially covered. “This enables the PCV to ensure precise and reliable positioning of the shuttles and pallets in real time,” explains Giacomo Volpe, Key Account Manager Automotive and Logistics/Material Handling at Pepperl+Fuchs Italy.
The read heads used in the warehouse shuttle have a reading window of 40 × 25 mm. This makes them very tolerant of lateral and vertical inclinations, enabling them to reliably read position data even on inclines or declines. To meet Eurofork's requirements, Pepperl+Fuchs has developed a special version with an exceptionally large working range of over 100 kilometers and a high precision of 0.1 millimeters.
Fully Traceable
“Thanks to absolute positioning, the pallets and shuttles in the warehouse can be located precisely at any time and are therefore fully traceable,” says Garola, describing the key advantage that the system offers in terms of transparency and process reliability. At the same time, precise positioning enables smooth and accurate machine movements. This allows the pallets to be stored as compactly as possible. “This is essential due to the high storage density in multi-deep warehouses. Optimized pallet positioning increases storage capacity without the need for structural expansion.” Overall, end customers benefit from faster order management, improved inventory control, and more efficient processes throughout the warehouse with the E4SHUTTLE.
Eurofork has even filed an international patent for the technology behind their pallet shuttles E4SHUTTLE and ESMARTSHUTTLE, which ensure absolute, precise, and reliable positioning. “The partnership with Pepperl+Fuchs enables us to be among the most competitive companies on the market in economic and, above all, technological terms,” says Garola, looking back on the collaboration with the automation specialist. Volpe also draws a positive conclusion: “Pepperl+Fuchs is not just a supplier to Eurofork, but has become a technology partner whose components contribute significantly to the company's unique solutions.”
PCV Data Matrix Positioning System
The Data Matrix positioning system PCV uses Data Matrix codes for precise positioning. It consists of a 2-D camera system—the read head—and Data Matrix code tapes or metal code bars. The code is attached to a fixed part of the system, while the read head is mounted on a vehicle moving parallel to it. This unique combination ensures maximum accuracy and reliability in positioning.
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