Materials Handling System: All You Need To Know

material handling equipment

In the world of industrial operations, the efficient movement, storage, and control of materials play a crucial role in ensuring productivity and success. This is where material handling systems come into the picture. A materials handling system refers to a set of equipment, processes, and technologies designed to facilitate the smooth flow of materials throughout various stages of production, distribution, and storage.

Types of Material Handling Systems

Engineered Systems

Engineered systems are customized solutions designed to meet specific material handling requirements. They are tailored to the unique needs of each business and may incorporate a combination of equipment and technologies.

AS/RS (Automated Storage and Retrieval Systems): AS/RS are computer-controlled systems that automatically store and retrieve goods from designated storage locations. They maximize storage capacity and facilitate efficient order picking.

Conveyor System: Conveyor systems consist of a network of belts, rollers, or chains that transport materials from one location to another. They are widely used in manufacturing and distribution facilities to move goods efficiently.

Automated Guided Vehicles (AGVs): AGVs are autonomous vehicles that transport materials within a facility without human intervention. They are programmed to follow predefined paths, making them ideal for repetitive material transportation tasks.

Robotics: Robotic systems are increasingly used in material handling operations. They can perform tasks such as palletizing, depalletizing, sorting, and picking, improving efficiency and accuracy.

Industrial Trucks

Industrial trucks are versatile vehicles designed for the movement and transportation of materials within a facility. They come in various types, each suited for specific tasks. Some common types of industrial trucks include:

Hand Trucks: Hand trucks, also known as dollies, are manually operated devices used for moving smaller loads. They are simple, cost-effective solutions for short-distance material transport.

Pallet Trucks: Pallet trucks, also called pallet jacks, are used for lifting and moving palletized loads. They are widely employed in warehouses and distribution centers.

Walkie Stackers: Walkie stackers are motorized vehicles that combine the functionality of a pallet truck and a stacker. They are capable of lifting and stacking palletized loads, providing greater flexibility in material handling tasks.

Platform Trucks: Platform trucks feature a flat platform for transporting larger and heavier items within a facility. They are commonly used in industries such as manufacturing and logistics.

Order Pickers: Order pickers are specialized trucks equipped with platforms or forks that enable operators to pick items directly from storage racks. They are essential in high-density storage environments.

Sideloaders: Sideloaders are designed for handling long and bulky materials, such as pipes or timber. They have the ability to load and unload materials from the side, making them suitable for narrow aisles.

Storage and Retrieval Systems

Efficient storage and retrieval systems are crucial for optimizing material handling processes. These systems ensure proper organization and accessibility of materials. Some common storage and retrieval systems include:

Racks: Racks are structures used for storing goods in a vertical manner. They come in various configurations, such as selective racks, drive-in racks, and push-back racks, allowing for efficient use of vertical space.

Stacking Frames: Stacking frames provide a sturdy framework for stacking items vertically, especially in situations where stacking in racks is not feasible. They are commonly used for storing items such as tires, drums, or large containers.

Shelves, Bins, and Drawers: These storage solutions offer convenient and organized storage for smaller items. Shelves provide horizontal storage space, while bins and drawers allow for segregated storage of small parts and components.

Mezzanines: Mezzanines are elevated platforms constructed within a facility to create additional storage space. They are useful for maximizing vertical space without the need for extensive building modifications.

Work Assist Tooling: Work assist tooling includes various devices and attachments designed to aid workers in material handling tasks. Examples include lift-assist arms, pallet positioners, and ergonomic lifting aids.

Pallet Inverters: Pallet inverters are specialized machines used to rotate or invert palletized loads. They are beneficial for tasks such as pallet exchange, product reorientation, or accessing items from the bottom of a stack.

Bulk Material Handling Equipment

Bulk material handling equipment is specifically designed for the efficient handling of large quantities of materials, such as grains, minerals, or liquids. Some common types of bulk material handling equipment include:

Conveyors: Conveyors, mentioned earlier in the engineered systems section, are extensively used for bulk material transportation. They ensure smooth and continuous movement of materials over long distances.

Stackers: Stackers are large machines used to stack bulk materials in stockyards or storage areas. They can create organized and stable stockpiles, allowing for efficient storage and retrieval.

Reclaimers: Reclaimers are used to extract bulk materials from stockpiles, such as coal or ore. They utilize rotating blades or buckets to reclaim the material and transfer it for further processing or transportation.

Bucket Elevators: Bucket elevators are vertical conveying systems used to lift bulk materials, such as grains or powders, from one level to another. They utilize buckets attached to a belt or chain to carry the material.

Grain Elevators: Grain elevators are specialized facilities used for the storage and handling of grains. They incorporate various equipment, such as conveyors, elevators, and bins, to facilitate efficient grain handling.

Hoppers: Hoppers are containers used for temporary storage or gravity feeding of bulk materials. They allow for controlled discharge of materials into downstream processes or equipment.

Silos: Silos are tall cylindrical structures used for storing bulk materials in large quantities. They provide airtight storage conditions to preserve the quality and integrity of the stored materials.

Elevated Lift Tables: Elevated lift tables are platforms with lifting mechanisms that can raise or lower materials to different levels. They are commonly used for loading and unloading tasks or to facilitate ergonomic material handling.

Cranes and Hoists: Cranes and hoists are heavy-duty equipment used for lifting and moving heavy or oversized materials. They offer precise control and maneuverability, making them essential for various industrial applications.

Benefits of Material Handling Systems in Industrial Operations

Efficient material handling systems offer numerous benefits to businesses operating in industrial settings.

Increased Productivity: Material handling systems streamline the movement of materials, reducing manual labor and the time required to transport and store goods. This, in turn, leads to enhanced productivity and faster turnaround times.

Cost Reduction: By optimizing material handling processes, businesses can reduce labor costs, minimize material wastage, and improve inventory management. These cost savings contribute to overall profitability and competitiveness.

Enhanced Efficiency: Material handling systems eliminate bottlenecks and inefficiencies by automating repetitive tasks and ensuring a smooth flow of materials. This enables businesses to achieve higher throughput and meet customer demands more effectively.

Improved Inventory Control: With effective systems in place, businesses can accurately track inventory levels, reduce stockouts, and avoid overstocking. This leads to better inventory control, reduced carrying costs, and improved customer satisfaction.

Safety Enhancement: Material handling systems prioritize workplace safety by minimizing manual lifting, reducing the risk of injuries, and ensuring proper ergonomics. They also incorporate safety features such as sensors and interlocks to prevent accidents.

Space Optimization: Efficient material handling systems make the most of available space by utilizing vertical storage, implementing compact storage solutions, and optimizing layouts. This allows businesses to maximize their storage capacity and optimize their facility's footprint.

Best Practices for Materials Handling System Maintenance

To ensure the optimal performance and longevity of material handling systems, it is important to follow best practices for maintenance.

Regular Inspection: Conduct routine inspections and lockout/tagout procedures of the equipment to identify and fix any signs of wear, damage, or malfunction. Address any issues promptly to prevent further damage and ensure safe operation.

Lubrication: Follow the manufacturer's guidelines for lubrication and apply lubricants as recommended. This helps reduce friction, minimize wear and tear, and extend the lifespan of the equipment.

Cleaning: Keep the material handling equipment clean and free from debris or obstructions. Regularly remove dirt, dust, and residue to maintain proper functionality and prevent potential hazards.

Operator Training: Provide comprehensive training to operators on the safe and correct operation of the material handling equipment. This reduces the risk of accidents, improves efficiency, and prevents unnecessary damage to the system.

Preventive Maintenance Schedule: Establish a preventive maintenance schedule that includes regular inspections, servicing, and component replacements. This proactive approach helps identify and address potential issues before they lead to major breakdowns.

Documentation: Maintain detailed records of maintenance activities, including inspections, repairs, and component replacements. This documentation provides valuable information for future reference, troubleshooting, and warranty claims.


1. What are the common challenges in material handling system implementation?
Implementing a material handling system can pose certain challenges. Some common ones include:

  • Identifying the most suitable system for specific operational requirements
  • Integrating the new system with existing infrastructure and processes
  • Ensuring compatibility between different components and equipment
  • Training employees to operate and utilize the system effectively
  • Managing the transition and minimizing disruptions during the implementation process
  • Allocating resources, such as time and budget, for system installation and maintenance
  • Adapting to changes in workflow and adjusting processes to accommodate the new system

2. How can a business ensure sustainable material handling practices?
To ensure sustainable material handling practices, businesses can:

  • Optimize Inventory Management: Implement effective inventory management systems to minimize excess inventory and reduce waste.
  • Embrace Lean Principles: Adopt lean principles such as just-in-time inventory, waste reduction, and continuous improvement to streamline operations and minimize resource usage.
  • Implement Recycling and Waste Management: Establish proper recycling and waste management programs to minimize the environmental impact of material handling activities.
  • Invest in Energy-Efficient Equipment: Choose energy-efficient material handling equipment and technologies to reduce energy consumption and lower carbon footprint.
  • Promote Reusable Packaging: Encourage the use of reusable packaging materials to minimize waste and reduce the need for single-use packaging.
  • Optimize Material Flow: Analyze and optimize material flow within the facility to minimize unnecessary movement, reduce handling steps, and increase efficiency.
3. What are the future trends in material handling systems?

The material handling industry is continuously evolving to meet the changing needs of businesses. Some future trends in material handling systems include:

  • Internet of Things (IoT) Integration: IoT technology is being integrated into material handling systems to enable real-time monitoring, data collection, and predictive maintenance. This helps optimize operations, enhance safety, and improve decision-making processes.
  • Artificial Intelligence (AI) and Machine Learning: AI and machine learning algorithms are being used to analyze data and optimize material handling processes. These technologies can optimize routing, predict maintenance needs, and improve overall system performance.
  • Sustainability and Green Initiatives: Businesses are placing greater emphasis on sustainability in material handling. This includes the use of eco-friendly materials, energy-efficient equipment, and waste reduction strategies to minimize environmental impact.
  • Enhanced Safety Features: Material handling systems are incorporating advanced safety features such as collision avoidance systems, proximity sensors, and intelligent monitoring to enhance workplace safety and reduce accidents.
  • Cloud-Based Solutions: Cloud-based platforms and software solutions are being utilized to centralize data, enable remote monitoring, and facilitate seamless integration between different components of material handling systems.

As technology advances, material handling systems will continue to become more efficient, intelligent, and sustainable, supporting businesses in achieving greater productivity and operational excellence.

The material provided in this article is for general information purposes only. It is not intended to replace professional/legal advice or substitute government regulations, industry standards, or other requirements specific to any business/activity. While we made sure to provide accurate and reliable information, we make no representation that the details or sources are up-to-date, complete or remain available. Readers should consult with an industrial safety expert, qualified professional, or attorney for any specific concerns and questions.


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Author: Herbert Post

Born in the Philadelphia area and raised in Houston by a family who was predominately employed in heavy manufacturing. Herb took a liking to factory processes and later safety compliance where he has spent the last 13 years facilitating best practices and teaching updated regulations. He is married with two children and a St Bernard named Jose. Herb is a self-described compliance geek. When he isn’t studying safety reports and regulatory interpretations he enjoys racquetball and watching his favorite football team, the Dallas Cowboys.