DJL Petfoods ‑ Pallet Shuttle Racking

The Challenge

DJL Petfoods’ existing storage and inventory process involved three separate stages, limiting unloading efficiency and the effective use of available space. The business needed a solution capable of handling bulk products while allowing regular pallet access.

A further challenge was the nature of the loads. Pallets could reach up to two metres in height and had limited load stability, making a standard pallet shuttle system unsuitable without modification.

Safety was also a priority. Machinery, storage zones and controlled-access areas needed to be securely segregated, while staff, equipment and critical infrastructure required greater protection from vehicle movements.

The Solution

Oakway designed and delivered an integrated storage and safety solution tailored to DJL Petfoods’ operational requirements.

The project included:

• A bespoke, semi-automated pallet shuttle with integrated weighing scales. Oakway manufactured the shuttle with slower acceleration and deceleration than a standard system, allowing it to transport pallets of up to 2 metres safely despite their limited load stability.
• Deep-lane pallet shuttle racking, providing efficient bulk storage while maintaining regular access to stock.
• A redesigned storage and inventory process that reduced the number of handling stages from three to two.
• Anti-collapse mesh fencing to securely separate machinery, storage zones and controlled-access areas.
• Industrial-grade safety barriers to protect employees, equipment and critical infrastructure.

The Outcome

The completed solution reduced unloading times by more than 50% and doubled DJL Petfoods’ storage capacity.

It also increased throughput, improved the organisation of stock movements and created a safer, more controlled working environment. The bespoke shuttle’s carefully managed movement made automated pallet handling a practical solution for DJL Petfoods’ unusually tall and less stable loads.