High-Bay Warehouse Automation
High-bay racking systems unlock maximum storage density — but only if you can reliably access every level. Autonomous reach trucks operate with millimetre precision at heights up to 9 metres, safely accessing every racking position in your facility and eliminating the height restrictions that limit manual operators.
Why High-Bay Goes Autonomous
High-bay warehouses represent the highest-value automation opportunity in material handling. The combination of expensive real estate, dense storage, and precision requirements creates a compelling case:
- Height unlocks value — each additional metre of usable racking height increases storage capacity by 15-20% without expanding your footprint
- Manual limitations — operator accuracy and confidence decrease above 6 metres; many sites restrict manual access to lower levels
- Narrow aisles at height — very narrow aisle (VNA) racking maximises density but demands precise operation that's challenging for human operators
- Safety regulations — working at height introduces additional WHS requirements and incident risks that automation eliminates
- Consistency — autonomous reach trucks deliver the same precision on level 7 as level 1, at hour 20 as hour 1
High-Bay Automation Capabilities
9-Metre Reach
Our 2.0T Reach Truck achieves 7-metre standard lift height with optional extension to 9 metres. Self-adaptive fork technology maintains precision throughout the full lift range.
Location Auto-Detection
LIDAR-based positioning identifies exact racking bay, level, and position. The system verifies location before every placement and retrieval, preventing costly mis-stores.
Narrow Aisle Navigation
Our reach trucks operate in aisles as narrow as 3.25 metres — compatible with VNA racking systems that maximise storage density. LIDAR guidance prevents aisle contact.
Cargo Overheight Detection
Optional sensors detect overheight loads before entering racking aisles, preventing the racking collisions that occur when pallets exceed the clearance height for their assigned level.
High-Bay Fleet Recommendations
| Application | Model | Max Height | Aisle Width |
|---|---|---|---|
| Standard high-bay | 1.4T Reach Truck | 5.5m (up to 8.3m) | 3.25m |
| Indoor/outdoor high-bay | 1.6T Reach Truck | 5.5m | 3.25m |
| Maximum height/capacity | 2.0T Reach Truck | 7.0m (up to 9.0m) | 3.30m |
| Lower-level putaway | 1.5T Pallet Stacker | 3.0m (up to 4.5m) | 1.42m |
Storage Density Impact
By reliably accessing all racking levels and operating in narrower aisles, autonomous reach trucks can increase effective storage capacity by 30-50% compared to manually restricted operations — without any physical building expansion. For warehouses paying $80-$150/m2 annually in rent, the space savings alone can deliver ROI within 12-18 months.