What is Material Handling? Principles, Benefits & Equipment 

While warehouses are known to be busy work environments with constant movement, they don&#;t have to be chaotic or labor-intensive, as long as the proper systems are in place. 

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With an organized material handling system and specialized equipment, warehouse operators can increase productivity and efficiency while keeping employees safe from potential accidents and streamlining the movement of goods from one stage to the next. 

But what is material handling exactly, and what does it entail?  

We&#;re about to find out. In this article, we&#;ll cover all you need to know about material handling, including how it&#;s implemented into the supply chain, the types of equipment used and the benefits of integrating it into your warehouse. 

Plus, we&#;ll share how our automated solutions fit into the material handling puzzle to help streamline your warehouse operations. 

What is Material Handling? 

Material handling is the movement of materials and goods from one location to another. It includes protecting, storing, and controlling the materials, from manufacturing to distribution. 

Material handling can be used across industries, but is typically utilized in warehousing, where goods need to be securely stored, retrieved, and shipped. 

Material handling equipment utilizes manual, semi-automated, and automated equipment to assist the movement and storage of materials within the warehouse. 

Types of Material Handling Equipment 

Material handling equipment is grouped into four main categories: storage and handling, bulk material, industrial trucks and engineered systems. Let&#;s take a look at each one. 

1. Storage and Handling Equipment 

Storage and handling equipment secures your goods while they aren&#;t being used or waiting for the next stage in the supply chain process. 

Storage and handling equipment can keep materials for short or long periods of time, depending on your warehouse&#;s needs. 

Storage and handling equipment includes: 

• Pallet racks: Vertical structures made of steel framing with connectors and beams to store products 
• Shelves, bins and drawers: Shelves, drawers and bins within shelving units store smaller materials. 
• Mezzanines: Wooden, steel or fiberglass raised platforms that create additional storage 
• Stacking frames: Equipment that stores and stacks numerous pallets and racks 

2. Bulk Handling Material Equipment 

Bulk handling material equipment stores, controls and transports loose form materials in large quantities. 

Loose form materials can include liquid, food and minerals, such as stones and rocks, and metal items, such as bolts and nails. 

Bulk handling equipment includes: 

• Conveyor belts: Two or more belts and pulleys to transport products from one location to another 
• Stackers: Equipment that loads and unloads heavy materials and places them onto stockpiles or storage for bulk materials 
• Reclaimers: Reclaimers are used to pick out materials from stockpiles 
• Bucket elevators: Designed for handling and lifting large amounts of bulk materials through the system 
• Hoppers: Funnel-shaped equipment used to dump or pour loose form materials into containers 

3. Industrial Trucks 

Industrial trucks are vehicles that transport goods and materials within your warehouse and are also utilized to load or unload heavy objects. 

There are several different types of industrial trucks. Some have forks or a flat surface to lift products, while others need additional equipment for lifting. Industrial trucks can range from small, hand-operated machines to large, drivable equipment. 

Industrial trucks include: 

• Forklifts: Industrial trucks that raise and lower goods in short distances 
• Hand trucks: Also called dollies, industrial trucks are manually pushed by hand and consist of two wheels and a small ledge to carry goods 
• Pallet Trucks: Also known as pallet jacks, pallet trucks are designed to lift and move pallets 
• Sideloaders: Industrial trucks that go through narrow aisles, and load and unload goods from the machine&#;s sides 
• Order pickers: These machines safely lift operators, allowing them to access hard-to-reach materials on high shelves 

4. Engineered Systems 

Engineered or automated systems are solutions that incorporate technology supported by computers and robots to store and transport goods 

An automated system is generally made out of several units, controlled by a management software application. 

Engineered systems include: 

• Autonomous mobile robots (AMRs): Sophisticated robots that navigate their environment independently, without the need for human intervention 
• Automated storage and retrieval systems (AS/RS): Computer-controlled solutions that keep and retrieve goods in the warehouse 
• Automated guided vehicles (AGVs): Guided robots that require a human operator to navigate their environment 

This is where Modula comes in. At Modula, we provide the most advanced automated storage and retrieval systems to increase productivity and accuracy throughout your warehouse.  

Our Vertical Lift Modules, Horizontal Carousels and Order Picking Solutions are designed to optimize space, reduce errors and speed up operations to create a seamless material handling process, from start to finish &#; more on this below! 

GF MACHINING SOLUTIONS: Vertical Storage Units Fully Integrated with ERP and Modula WMS. 

Benefits of Material Handling 

An effective material handling system allows your company to have the necessary stock in smaller spaces where possible, reduce time spent on internal operations (such us transport and picking), control inventory in real-time, reduce operational costs and optimize the overall flow of goods in your facility. 

From preventing workplace accidents to saving you money, here are four reasons why material handling is key to implement in your warehouse. 

1. Prevents Workplace Accidents 

According to a recent survey, overexertion is the most disabling United States workplace accident in , with falls and being struck by an object ranking second and third, respectively. 

With materials handling systems and the proper equipment, employees aren&#;t required to lift heavy items and reach high storage areas. 

2. Improves Employee Satisfaction 

Job discomfort causes frustration, low morale and loss of motivation in employees. 

By utilizing materials handling systems, employees are released from labor-intensive (for example, lifting heavy items) and monotonous tasks that will help them reduce stress levels and achieve overall satisfaction with work. 

3. Increases Productivity and Efficiency 

Want your employees to focus on more pressing tasks such as quality control assurance? 

Material handling equipment can help your employees transport, locate, and pick inventory, allowing them to be more competent and productive with other tasks. 

4. Saves You Money 

According to a report, the worldwide expenditure of warehousing companies is tallied at a whopping &#;300 billion each year. 

To prevent spending more on equipment damage, invest in quality solutions and educate your employees on the proper equipment maintenance. 

How is a Materials Handling System Implemented Throughout the Supply Chain?  

From manufacturing to distribution, material handling is key to ensure your materials and goods are safely transported from one stage of the supply chain to the next.  

Here&#;s how material handling is implemented in the supply chain:  

• Manufacturing: Material handling is used to move and manage inbound shipments within storage areas or a warehouse. 
• Transportation: Material handling is used to place goods on pallets for easier transportation to warehouse storage areas. 
• Storage: Material handling is used to safely offload goods to designated storage areas or shelves while they wait for distribution. 
• Distribution: Material handling is used to load goods onto trucks (for example, using forklifts) that will be delivered to retailers, wholesalers or customers. 

10 Material Handling Principles to Streamline Your Operations 

Researchers and professionals at the Material Handling Institute created a document containing the 10 principles of material handling to create a safer and more productive materials handling system. 

From reducing unnecessary manual work to maximizing available space and tracking inventory in real-tine, Modula&#;s automated solutions are designed to help you adhere to these principles to streamline your warehouse operations. 

1. Planning: Establish a clear plan for your material handling system. Your plan should identify which materials will be transported, which equipment will be used and where your materials will be stored. 

2. Standardization: Standardize your process and equipment to achieve predictable results while considering flexibility. For example, if you have boxes of the same size, your team should anticipate future changes regarding box sizes, so you can choose equipment that can efficiently transport smaller or larger boxes in the future. 

3. Work: Reduce unnecessary work by using equipment that will minimize or eliminate repetitive tasks. 

4. Ergonomics: Acknowledge your employees&#; restrictions and capabilities by investing in ergonomic equipment to ensure safety in the workplace.  

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5. Unit load: Utilize unit loads such as containers and pellets to reduce effort and walking time in the warehouse. 

6. Space Utilization: Organize your warehouse to maximize your available warehouse space. You can ensure your warehouse is organized by clearing warehouse aisles from clutter, stacking inventory to utilize vertical height and grouping products in the same category. 

7. System: Integrate tracking tools so you can quickly identify materials and products at every stage of the system.  

8. Environment: Use equipment that will reduce energy consumption and prevent greenhouse gas emissions. For example, using an electric forklift is more sustainable than using a liquid-propane powered truck. 

9. Automation: Implement automation in warehouse processes such as picking and retrieval to lower costs and boost employee productivity. 

10. Life Cycle Cost: Utilize a comprehensive analysis of life cycle costs on material handling equipment to ensure durability and sustainability. Consider different criteria, including programming, installation, setup, operation, repair and maintenance, reuse value and disposal.

How Modula&#;s Solutions Contribute To A Seamless Material Handling Process 

At Modula, we take material handling to the next level using the most advanced automated storage and retrieval systems. Our automated solutions boost accuracy and productivity, improve employee safety and reduce storage space requirements.  

Modula Vertical Lift Modules 

Modernize your warehouse operations by going vertical with three options: 

• Modula Lift is the optimal storage solution for industrial materials, spare parts and components for every industry and workplace environment 
• Modula Slim is the ideal solution for warehouses with minimal floor space requiring flexible storage options 
• Modula OnePick is the perfect automated solution that integrates technological innovations into your conveyor systems and AGVs to pick and extract goods 

Our Vertical Lift Modules allow you to: 

• Keep your employees safe by eliminating the challenges of reaching high and low areas 
• Improve efficiency by retrieving the items needed from a small number of VLM stations 
• Safeguard your products by storing them in an enclosed setting that only designated employees can access 

• Increase productivity thanks to picking speeds of 300 lines per hour 
• Lower operational cost as well as employee cost 
• Anticipate requirements and offer the possibility for future growth 
• Pay off the investment rapidly, with an ROI anywhere from six to 18 months 

Modula Horizontal Carousels 

Modula Horizontal Carousels turbocharge your warehouse operations when ceiling height is limited. 

Our Horizontal Carousels allow you to: 

• Facilitate quick and accurate picking operations with put-to-light systems and barcode readers 
• Increase picking rates of up to 550 lines per hour for each warehouse operator 
• Monitor picking operations in real-time thanks to automation 
• Find and retrieve goods quickly with Modula&#;s digital Copilot 

Modula Warehouse Management Solutions 

Pair your automated storage systems with our warehouse management solutions to boost productivity, accuracy and efficiency. 

Warehouse management solutions offer better control over inventory tracking, materials handling, process analysis and preventive maintenance guidance. 

Our smart solutions allow you to operate in multi-order and batch modes to increase productivity without compromising your order fulfillment process for larger than usual orders. 

Modula Cloud is a support and remote warehouse management platform that collects data from your AS/RS wherever they are in your warehouse. 

With Modula Cloud, you can: 

• Manage and monitor your warehouse operations in real-time, 24/7 
• Gather your data in an easy-to-navigate online portal 

Key Takeaways on Material Handling  

More than just the movement of goods and products, material handling is a crucial element in your warehouse operation because it provides a standardized process of handling and transportation from manufacturing to distribution. 

At Modula, our automated solutions are designed to integrate into each stage of the supply chain and help you follow the key principles of material handling to ensure a seamless operation. 

Take your material handling to the next level with the most advanced storage and retrieval systems from Modula. 

Take a moment to think about the multitude of equipment and systems that interact with your inventory daily. All that &#;stuff&#; falls under the umbrella of material handling, and it has a massive impact on the efficiency and profitability of your business. Let&#;s look closely at material handling and the benefits of getting it right.

What is Material Handling?

In the business world, material handling is all about moving, storing, controlling, and safeguarding materials and products during manufacturing, warehousing, and distribution and throughout the consumption and disposal processes. Material handling questions and solutions are part of any manufacturing or logistics project, and any attempts to improve efficiency or productivity must involve conversations about material handling.

• Want to ramp up your production to meet new sales targets? You&#;ll need to address how you will store the inventory increases. That&#;s material handling.
• Interested in improving pick rates? Reorganizing your warehouse to put top SKUs in more convenient locations will help with picking speeds. That&#;s material handling.
• Want to install a conveyor system to move orders from the picking floor to distribution? That&#;s material handling.

Material handling can be divided into four general categories:

Non-automated Material Storage and Handling.

This category refers to equipment that stores materials at times when they are not being used or transported, short or long-term. Examples include shelves, bins, drawers, stationary and moveable racks, pallets, stacking frames, mezzanines, and many others. Getting this type of material handling equipment right helps maximize space and provides easy access to needed materials

Automated Systems

Automated systems, sometimes called engineered systems, can help with both storage and transportation. An example of an automated material handling system that does both is an Automated Storage and Retrieval System (AS/RS) that stores and retrieves inventory on demand.

Other examples of automated systems include conveyors, AGVs (automated guided vehicles), and robotic systems. While these three involve different engineering, the idea behind them &#; to move materials between locations automatically in the most efficient way possible &#; is the same.

Industrial Trucks

These aren&#;t trucks for driving on the road, they&#;re trucks used inside to move materials around the warehouse or manufacturing floors. Some industrial trucks are hand operated while others can actually be driven. Examples include forklifts, side loaders, hand trucks, and pallet jacks.

Bulk Material Handling

These systems are made to store, manage, or move very large quantities of material. Some automated conveyor systems can fall into the bulk material handling category, as do grain silos, hoppers, stackers, reclaimers, and others.

Why Do You Need to Get Material Handling Right?

It bears repeating: all your raw materials and everything you make and sell come into contact with material handling systems and equipment. All of it. The power of leveraging the relationship between productivity and material handling cannot be overstated. Here are just a few of the benefits:

Less Manpower

People are expensive and slow. Anything you can do to reduce the number of people it takes to do tasks such as sorting, picking, transporting, and shipping will speed things up and save money.

Maximize Space

You need enough space on the warehouse and production floors to store everything you need to store and to allow your staff and equipment to maneuver freely and easily in order to access everything you&#;ve got stored. A crowded space is an inefficient space. Storage and handling equipment helps you use your space efficiently while still providing the access needed to accomplish daily operations.

Decrease Damages

People drop things, but so does the wrong material handling equipment. When materials aren&#;t handled correctly, damages occur. Having the right solutions in place to move materials safely decreases the rate of product damage. Replacing damaged materials results in unnecessary costs and time delays.

Improved Customer Service

Solid material handling solutions tailored to your business means your customers are more likely to get what they want when they want it. Accuracy improves, as do delivery times, both of which lead to happy, loyal customers.

Increased Efficiency and Productivity

Material handling solutions improve efficiency and productivity in countless ways. In addition to those improvements already mentioned, implementing modern material handling gets more work done in less time. There&#;s less fatigue, fewer errors, shorter trips, and more speed when the right systems and equipment are in place.

Fewer Accidents

Moving large quantities of material manually is rough on employees. Solutions such as lift trucks and conveyors take the burden off your people and prevent the risks of health problems related to over-exertion or repetitive motions. The right approach to material handling improves the safety of your crew and reduces the number of work-related injuries, which is good for you and your staff.

Better Employee Satisfaction

The best equipment makes your facility a good place to work. Your employees will appreciate having the right equipment to get their jobs done safely, and they&#;ll stay. Morale is also better when injury rates are low and when workers don&#;t have to spend time on problems like fixing errors or searching for missing items. Plus, word will get &#;round that you take care of your staff, making attracting good workers easy. A positive workplace and a culture of caring are good for your people, productivity, and business.

Boosted Bottom Line

Everything comes down to money, and material handling is no exception. As your profit margins tighten, finding ways to save money becomes critical to boosting your bottom line. Yes, investing in material handling equipment costs money, but the productivity and efficiency improvements it brings &#; when done right &#; can save big bucks over the long term. All the benefits listed here have a direct and measurable impact on the bottom line.

Talk to Indoff Today

Are you ready for material handling solutions? We&#;ve got you covered if you need a high-tech conveyor system, ideas for speeding up your warehousing processes, more space for inventory growth, or robots to make your materials flow fast and smooth. Indoff is a trusted material handling distributor and supplier.

If you&#;ve got material handling questions, Indoff has the answers. Call us today to find out what we can do for you.