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Automated Shuttle System for Material Transfer in Manufacturing

The SESTO Shuttle System, powered by the Magnus AMR platform, extends production lines by bridging conveyors, racks, and automated work cells with AMRs. Equipped with a motorized roller top, it transfers totes and trays to fixed conveyor lines, eliminating manual handling and transfer. It ensures seamless, traceable material flow across manufacturing environments.

Challenges
  • Manufacturers needed to automate the transfer of materials between conveyors and storage zones to minimize manual handling and downtime.
  • The existing process required operators to manually align and roll heavy trays or pallets between equipment, causing inconsistency and workflow delays.
  • Precise alignment was critical to prevent product damage and maintain throughput quality.
Solutions
  • Automated transfer: The SESTO Shuttle System was deployed to automate load transfers between fixed conveyor lines and mobile AMRs.
  • Motorized conveyor top: Enables smooth, bi-directional transfer of totes, trays, and pallets with precise alignment.
  • Laser-guided docking: Ensures every connection between AMR and conveyor is accurate and repeatable.
  • Sensor-based verification: Confirms that each load is securely received and delivered before the AMR departs.
  • Fleet coordination: The fleet management system synchronizes AMR movements with MES or ERP for complete operational visibility.
Outcome
  • Material Movement: Enabled continuous, hands-free material movement across production floors.
  • Improved throughput: Reduced manual intervention
  • Achieved shorter transfer cycles and safer handling.
  • Increased consistency and uptime across production lines.
  • Reduced operator fatigue and overall labor requirements.