LoadRunner Plus: Non-Modified ATLS for Automated One-Shot Pallet Loading & Unloading

Technology Overview

In the realm of intralogistics and supply chain operations, truck loading and unloading has long been a bottleneck due to its reliance on manual labor or semi-automated processes that are time-consuming, prone to errors, and limited in throughput. The need for a fully automated solution that can integrate with existing non-modified trucks and trailers without extensive infrastructure upgrades has driven the development of advanced Automated Truck Loading Systems (ATLS). LoadRunner Plus, a non-modified ATLS solution from Ancra Systems, addresses this pain point by focusing on one-shot, fully automated pallet handling for standard Euro pallets.

The core principle of LoadRunner Plus revolves around its unique All Axis positioning and alignment technology, which eliminates the need for human intervention and enables precise, high-speed loading and unloading. Unlike conventional forklift-based loading or modified ATLS solutions that require truck or facility alterations, this system is designed to work with standard, non-modified trucks, trailers, and containers, making it a versatile option for a wide range of logistics and manufacturing operations. Its primary application areas include 3PL distribution centers, manufacturing facilities with high-volume transport needs, and wholesale B2B operations that utilize standardized Euro pallet systems.

How It Works

Core Principles

The fundamental principle of LoadRunner Plus is fully automated All Axis positioning and alignment, which allows the system to precisely maneuver and place pallets without human input. The system uses skate-based mechanisms that function as long forks, sliding underneath the base of Euro pallets to lift and transport them. A key design principle is minimizing the vertical clearance of pallets during loading—with pallets hovering just 15-20mm above the trailer floor—this maximizes the use of available space inside the trailer and reduces the reserved free space required compared to conventional forklift loading. Additionally, the system is engineered to eliminate queue pressure between individual pallets, which prevents product damage during the handling process.

Key Features & Capabilities

The fully automated All Axis positioning and alignment functionality is the defining feature of LoadRunner Plus, as it enables the system to achieve one-shot loading and unloading of 33 Euro pallets without any human intervention. This level of automation eliminates the variability and inefficiency associated with manual or semi-automated processes, ensuring consistent and precise handling of pallets every time. The All Axis system allows for dynamic adjustments to accommodate minor variations in trailer positioning, making the solution robust and adaptable to real-world operational conditions.

A critical capability of LoadRunner Plus is its compatibility with non-modified standard trucks, trailers, and containers. Unlike many ATLS solutions that require modifications to vehicles or dedicated trailer fleets, this system works with existing standard equipment, significantly lowering the barrier to adoption for logistics and manufacturing operations. This compatibility extends the utility of the system across different supply chain partners, as it does not require standardized vehicle fleets to function effectively. Additionally, the system supports partial loading operations, providing flexibility for scenarios where a full load of 33 pallets is not needed, which enhances its applicability for mixed-load shipments.

The skate-based long fork mechanism is another key feature that drives the system’s space efficiency. By sliding underneath pallets and maintaining a minimal 15-20mm vertical clearance above the trailer floor, the system maximizes the use of available space inside the trailer. This design reduces the reserved free space required compared to conventional forklift loading, where larger clearances are necessary for maneuvering. Furthermore, the absence of queue pressure between individual pallets prevents product damage during handling, which is a common issue with conventional loading methods that involve stacking pallets under pressure.

Advantages & Benefits

LoadRunner Plus delivers dramatic performance improvements in truck loading and unloading operations, with the most significant benefit being the reduction of cycle time from 35 minutes to just 3 minutes per trailer. This 10x reduction in cycle time directly translates to increased throughput at dock doors, with a single dock able to handle 3-4 full trailer cycles per hour. For high-volume distribution centers and manufacturing facilities, this throughput increase eliminates bottlenecks in the shipping and receiving process, enabling faster turnaround of vehicles and more efficient use of dock resources.

The elimination of human intervention brings multiple operational benefits, including improved workplace safety and reduced labor costs. By removing workers from the loading/unloading process, the system eliminates the risk of injuries associated with manual pallet handling and forklift operations. Additionally, operations no longer need to allocate labor resources to this repetitive task, allowing staff to be redeployed to higher-value activities such as inventory management, quality control, and order fulfillment. The fully automated process also eliminates human error, ensuring consistent loading quality and reducing the risk of pallet misalignment or product damage.

From a space utilization and cost-effectiveness perspective, LoadRunner Plus maximizes the usable space inside trailers by minimizing vertical clearance during loading. This means more pallets can be loaded per trailer (or the same number of pallets in a more compact footprint), reducing the number of vehicles required for transport and lowering overall logistics costs. The system also avoids product damages by eliminating queue pressure between pallets, which reduces the cost of damaged goods, returns, and replacements. Furthermore, the compatibility with non-modified vehicles eliminates the need for capital expenditure on specialized trailer fleets, making the solution a cost-effective upgrade for existing operations.

Implementation Considerations

Implementing LoadRunner Plus requires dedicated dock door setup to integrate the system with the facility’s existing intralogistics infrastructure. While the system works with non-modified trucks and trailers, the dock door area must be configured to support the All Axis positioning system and skate-based fork mechanism. This may involve modifications to the dock’s loading zone, staging area for pallets, and control system integration, which should be factored into the implementation timeline and budget.

A key consideration is the system’s optimization for standard Euro pallets with short side orientation. While this aligns with the pallet standards used in many European and global supply chains, operations that utilize non-standard pallet sizes, dimensions, or orientations may face limitations. For these operations, custom adjustments or additional modules may be required to adapt the system, which can increase implementation complexity and costs. It is important to assess pallet standardization before adopting the solution to ensure compatibility with existing inventory handling processes.

Integration with existing warehouse management systems (WMS) or warehouse execution systems (WES) is another factor to consider. To fully leverage the system’s throughput capabilities, LoadRunner Plus should be integrated with the facility’s inventory and shipping systems to enable automated task triggering, pallet staging, and vehicle scheduling. Facilities with legacy WMS may need to invest in integration tools or middleware to ensure seamless communication between the ATLS and existing software platforms.

Use Cases & Applications

Ideal For

LoadRunner Plus is ideal for operations that handle high volumes of standard Euro pallets and require fast truck turnaround times. It is particularly suited for 3PL distribution centers, manufacturing facilities with just-in-time (JIT) supply chains, and wholesale B2B operations that ship large quantities of goods via standard trucks and trailers. The solution is also well-suited for facilities looking to improve workplace safety by eliminating manual pallet handling and forklift operations in the loading/unloading zone.

Performance Metrics

• Loading/Unloading Cycle Time: Reduced from 35 minutes to 3 minutes per full trailer load
• Dock Throughput: 3-4 full trailer cycles per hour per single dock door
• Pallet Clearance: 15-20mm above trailer floor during loading, minimizing reserved free space
• Pallet Capacity: 33 standard Euro pallets (short side orientated, 3 pallets side by side) per one-shot load

Conclusion

LoadRunner Plus from Ancra Systems represents a transformative solution for automated truck loading and unloading, addressing a critical bottleneck in supply chain operations with its fully automated, one-shot handling capability. The system’s compatibility with non-modified trucks and trailers, space-efficient design, and dramatic cycle time reduction make it a valuable investment for 3PL, manufacturing, and wholesale B2B operations that utilize standard Euro pallets. By eliminating human intervention, improving workplace safety, and maximizing dock throughput, LoadRunner Plus delivers significant operational and cost benefits, enabling facilities to optimize their shipping and receiving processes without extensive capital expenditure on specialized vehicle fleets. For operations looking to upgrade their intralogistics performance and reduce trailer turnaround times, LoadRunner Plus is a robust, efficient, and cost-effective ATLS solution.

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