What Is Material Handling Equipment?

Material handling equipment includes the machinery and storage needed to move, store, control, and protect materials in manufacturing and warehousing. Material handling equipment forms the foundation of industrial operations to ensure a smooth and efficient workflow from material intake to finished delivery.

What Are Examples of Materials and Equipment?

Some of the more common material handling equipment examples include:

• Storage solutions such as pallet racks, push back racks, drive in racks, shelving, and mezzanines
• Material movement equipment, such as conveyors and pallet flow racks
• Forklifts, pallet jacks, lifts, and other machines
• Robotic and automation systems, such as Automated Guided Vehicles (AGVs), Autonomous Mobile Robots (AMRs), and Automated Storage and Retrieval Systems (AS/RS)

What Four Functions Must All Material Handling Equipment Perform?

Effective material handling equipment and material movement equipment must consistently execute one or more of these four functions:

1. Transportation: Moving materials from one location to another within a facility or between different facilities. This includes horizontal, vertical, and diagonal movement of goods.
2. Lifting and Positioning: Raising, lowering, and precisely positioning materials to facilitate processing, storage, or loading. This function ensures materials can be manipulated with minimal human labor.
3. Storage and Buffering: Providing storage solutions that protect materials, optimize space utilization, and maintain inventory accessibility. This function helps manage material flow and inventory control.
4. Unit Load Formation: Consolidating individual items into manageable loads that can be efficiently moved, stored, and tracked. This function simplifies material handling and reduces the complexity of moving multiple items.

What Are the Four Major Categories of Material Handling Equipment?

Material handling equipment can be categorized into four primary groups:

1. Manual handling equipment
2. Automated equipment
3. Storage
4. Industrial vehicles

Manual Handling Equipment

These are human-powered tools that require direct humans to operate, such as:

• Hand trucks
• Dollies
• Pallet jacks
• Manual lift tables
• Hand carts
• Portable conveyor rollers

Automated Equipment

Automated machines from a material handling equipment supplier can significantly improve your workflow and efficiency. A study by the McKinsey Global Institute reports that automation can improve productivity by more than 70% in some functional areas.

Automating manufacturing material handling equipment can reduce reliance on labor, especially for low-skill jobs that are hard to fill and typically result in high turnover rates.

Automated equipment includes:

• Conveyor systems
• Automated guided vehicles (AGVs)
• Robotic material handlers
• Automated storage and retrieval systems (AS/RS)
• Sortation systems
• Automated picking robots

Much of the investment over the past few years has centered on automation, and that trend is likely to continue. The global market for automated material handling equipment is forecast to grow from $33.3 billion in 2024 to $51 billion by 2029—a growth rate of about 9% a year.

Storage Equipment

In manufacturing, storage equipment plays an important role. Holding, securing, and organizing inventory, material, work-in-progress, and finished goods requires an efficient system and equipment.

Storage equipment includes items like:

• Pallet racks
• Shelving units
• Mezzanine platforms
• Vertical lift modules
• Drawer cabinets
• Bin storage systems
• Mobile shelving

Industrial Vehicles

Powered mobile equipment for material transportation is another area where manufacturers are making investments, making work more efficient.

Industrial vehicles for material handling include:

• Forklifts (counterbalance, reach, side-loading)
• Overhead cranes
• Tuggers and tow tractors
• Order pickers
• Scissor lifts
• Pallet trucks

What Are the Key Benefits of Material Handling Equipment?

Implementing appropriate material handling equipment in an optimal configuration and workflow can produce significant advantages.

Increased Productivity

Automated and efficient equipment accelerates material movement, reducing cycle times and enabling faster production.

Reduced Labor Costs

By minimizing manual handling, and automating repetitive tasks, you can lower workforce requirements and labor expenses. This has become a prime area of concern for manufacturers due to an aging workforce, retirement, and increasing labor shortages. A 2024 study in Global Trade magazine reports that 37% of organizations surveyed reported high labor shortages. Nearly 60% reported these shortages impacted their ability to serve their customers.

With challenges in recruiting and retaining workers, along with higher overall wages, reducing labor costs has become imperative in the industry. Material handling and material movement equipment are making a big difference in solving these challenges.

Improved Safety and Ergonomics

Manufacturing environments can be prone to workplace accidents and injuries. According to the National Safety Council (NSC), warehousing, transportation, and manufacturing are among some of the most dangerous industries.

Modern material handling equipment can automate many of the tasks that put physical strain on workers. This reduces injury risks and, and creates safer working environments.

Reduced Material Damage and Waste

Precision handling equipment decreases the likelihood of material damage during transportation and storage, leading to lower replacement costs and improved product quality.

Better Inventory Management

Advanced tracking and storage systems provide real-time visibility into inventory levels, locations, and movements, enabling more accurate and efficient inventory control. Material handling equipment and storage solutions can optimize space utilization and automate inventory tracking for better accuracy.

Different types of storage solutions can also handle bulk, palletized, or individual items, organizing different types of inventory for more efficient and easier retrieval.

What Are New Innovations in Material Movement Equipment?

Innovative solutions on the market are making a big difference in manufacturing operations. The Industry 4.0 movement is going full steam ahead.

The Global Industrial Robotics Survey by McKinsey revealed that 80% of companies are adopting advanced automation and robotics. Material handling equipment and material movement equipment are now about more than the efficient storage and movement of goods. They are increasingly becoming intelligent and connected to improve operations.

Here are some of the current and emerging technologies that manufacturers, distributors, warehouse operators, and fulfillment centers are implementing.

How to Choose the Right Manufacturing Material Handling Equipment

Selecting the right material handling equipment for your manufacturing facility is a critical decision, and there is a wide range of options available. Here are some key factors to consider.

Assess Your Operational Needs

Start by evaluating the requirements of your manufacturing processes. Consider:

• Material types: Are you handling raw materials, finished goods, or hazardous items?
• Load size and weight: Ensure the equipment can handle your heaviest and largest items.
• Frequency of use: High-use applications may benefit from automated systems.

For example, a facility that frequently moves large pallets might benefit from forklifts or automated pallet jacks, while a manufacturing line handling lightweight items could choose conveyor belts or robotic arms.

Prioritize Safety and Ergonomics

Manufacturing material handling equipment should enhance workplace safety and reduce the risk of injuries. Features like anti-collision sensors, adjustable height mechanisms, and automated controls can protect workers while improving ergonomics.

If your facility involves repetitive lifting, consider solutions like scissor lifts or vacuum lifters to minimize strain.

Evaluate Space Constraints

Measure your facility’s layout to ensure the equipment fits seamlessly. Narrow aisles may require specialized forklifts, while vertical storage solutions like Automated Storage and Retrieval Systems (AS/RS) can optimize space in facilities with a limited floor area.

Consider Future Growth

Choose equipment that can adapt as your operations grow or change. Modular conveyor systems, for example, can be expanded or reconfigured to meet increasing production demands. Similarly, investing in automation-ready equipment can future-proof your facility against evolving industry trends.

Your material or inventory mix may change over time as well, so make sure your storage solutions can adapt to changing needs.

Assess Energy Efficiency and Sustainability

Look for equipment designed to minimize energy consumption. For example, electric forklifts are a green alternative to gas-powered models, and smart conveyor systems can reduce power usage by operating on demand.

How to Choose a Manufacturing Material Handling Equipment Supplier

Finding a reliable supplier for material handling equipment is just as important as choosing the right equipment. A trustworthy partner will ensure you receive quality products and long-term value.

Evaluate Industry Expertise

Look for a supplier with a proven track record in manufacturing material handling. An experienced supplier will understand industry challenges and offer customized solutions.

Check Product Quality and Range

A reliable supplier will offer high-quality equipment from reputable brands.

Assess their product range to ensure they can meet all your material handling needs. A supplier offering conveyors, storage solutions, and lifting equipment simplifies procurement and ensures compatibility.

Assess Customization Options

Manufacturing facilities often have unique needs. Choose a supplier that offers customization, such as designing storage racks for non-standard items or modifying conveyor systems to fit specific workflows.

Consider Service and Support

The best material handling equipment suppliers provide more than just equipment. Depending on your needs, opt for a full-service supplier that offers:

• Planning and engineering: Help with designing and optimizing your equipment choice, facility layout, engineering, and permitting.
• Installation services: Ensure your equipment is set up correctly, including specialized labor if needed for set-up, teardowns, or moves.
• Technical support: Quick access to experts to help you maximize your operations.
• Warranties: Industry-standard or better warranties to protect your investment.

Review Reputation and References

Check online reviews and ask for references from other manufacturing companies. A supplier with positive feedback and long-term customer relationships is more likely to deliver dependable service.

When you get references, talk to them directly. This allows you to hear first-hand about how a supplier approached the project and the results.

Evaluate Pricing

While cost is important, avoid suppliers offering significantly lower prices than competitors, which is likely to mean lower quality. Instead, focus on suppliers offering competitive pricing and focus on the total cost of ownership (TCO). It may be worth spending a little more upfront if you can reduce your overall costs and produce a stronger ROI.

Frequently Asked Questions­—FAQs

What are the four elements of material handling?

The four elements are movement, storage, control, and protection, which ensure materials are transported, stored, tracked, and safeguarded against damage.

How do automated material handling systems improve efficiency?

Automated material handling systems reduce manual labor, increase speed and accuracy in operations, and minimize errors.

How do I choose the right material-handling equipment for my business?

Assess your needs based on material types, load sizes, space constraints, and future scalability while prioritizing safety, durability, and cost-effectiveness. Work with a reputable material handling equipment supplier with experience in your industry.

Contact Conesco Storage Systems to talk to the experts in manufacturing material handling equipment to optimize your operations.