What does Material Handling entail: The Definitive Guide

Effective material handling forms the cornerstone of successful supply chain logistics. Once integrated, operational strategies must adapt to growing supply and demand, as well as advances in technology and tools. Let's explore the fundamental principles of managing your goods and raw materials, and look at some of the tools TAWI provides to enhance your operations.

What is material handling?

By dictionary definition, material handling refers to "the loading, unloading, and movement of goods, as within a factory or warehouse, especially by mechanical devices." Put simply, the process includes moving, storing, protecting, controlling, and processing products and materials. It's how you manage your warehouse space — making sure you move, store, protect, control and process products and materials as effectively as possible. Processing typically blends manual and semi-automated techniques, with greater automation generally yielding better results. This is where we can help.

In practice, effective material handling covers:

• The efficient processing and tracking of unit loads and individual goods from arrival to departure.
• Unloading the raw materials and parts required to create or assemble products.
• Safe and compliant storage of raw materials and goods on organised pallets and racks.
• Organising strategic unit loads to optimise manufacturing and order processing.
• Retrieving raw materials, supplies, and products to process, package, and ship.
• Loading to ship to a distribution centre or directly to a B2B or B2C client.

The benefits of strategic materials handling

Tailored strategies go beyond standard inventory management, as they deliver on numerous KPIs, including:

• Reduced labour spending — manual handling consumes 25% or more of labour spending. This number can be drastically reduced with semi-automation.
• Throughput — manual handling consumes up to 87% of production time. Semi-automated processes drastically improve loading, picking, unloading, and processing times.
• Manufacturing costs — inefficient operations account for 70% of manufacturing costs.
• Waste and damage — manual practices increase the odds of product damage and misplaced goods.
• Internal risk — semi-automated and automated systems ensure safe social distancing, improved ergonomics, and reduced injury.
• Improved job satisfaction — employees want a strategic approach to minimise burnout, boredom, injury, and turnover.
• Compliance — modern technology and tools are designed to support industry and regional compliance, including ATEX zones and cleanroom compliance.
• Customer service — the faster you produce goods and process your orders, the happier your end consumer will be.
• Order accuracy — semi-automated strategies increase picking and shipping accuracy from 97% to 99%.

Universal principles of efficient material handling

There are ten universal principles for implementing materials handling in logistics. These principles are practical regardless of business type, product type, warehouse layout, or order volume. However, they must be built upon as your product mix and order/processing volume increase and as software and technology advance.

#1 Strategic planning

The first step is defining your initial needs or current areas of opportunity. Then you can start exploring solutions. These can include a better layout, software upgrades, and finding the best semi-automated tools and technology.

# 2 Agile and standardised

An exciting thing about semi-automating your material handling is that it lets you cross-train your employees. It also empowers you to employ more team members with entry-level skill sets.

#3 Functional

The system must work. It must provide a simple way to move items to and from designated areas in the warehouse. The route must be as streamlined and strategic as possible. Don't be shy about asking for employee input, as they often see areas of opportunity.

#4 Safe and ergonomic

Even if the load is light, repetitive bending, reaching, lifting, and transferring goods leads to physical burnout. Utilising industrial hoists and vacuum lifters improves ergonomics, minimising risk and enhancing job satisfaction. This includes systems that utilise gravity to your benefit.

#5 Move in loads

Moving one item at a time is inefficient. With the exception of large and bulky items, such as heavy canisters or large sheets, items should be moved in bulk for as much of the process as possible. This includes moving multi-item boxes, full pallets, containers, and totes.

#6 Space utilisation

Both vertical and horizontal space should be considered when implementing efficient materials handling in logistics — even where the plant or warehouse areas are narrow or have low ceilings. This often calls for a mix of forklift-mounted, ceiling-mounted, and stationary lifting tools.

#7 A to Z systematic

Implementing a coordinated system that handles all materials from arrival to departure. This includes any combination of:

• Processing incoming deliveries
• Unloading and inspecting
• Moving, unitising, and storing
• Production of raw goods
• Assembling parts
• Picking and packaging
• Labelling and shipping
• External shipping
• Returns handling

#8 Environmental sustainability

Prioritizing the environment saves energy and material costs. It can improve operational safety and attract aligned consumers. This includes hazardous materials handling, recycling, and reusing waste.

#9 Semi-automated

From push-button or joystick lifts and pickers to hoists, cranes, and trolleys.This includes forklifts, conveyor belts, robotics, and tools that reduce manual lifting or picking. We dive into some of your top options further below.

#10 Lifecycle sensitive

Upgrading tools and technology is an investment that pays back through lower labor costs. It also improves risk management and boosts throughput. Be sure to calculate your lifecycle costs, including your:

• Capital investment
• Setup and installation
• Programming
• Training
• System testing
• Operational costs
• Maintenance and repairs
• Recycle and reuse potential
• Downtime for the transition

The three primary types of materials handling

Few operations are fully manual, and small production and fulfillment plants may have little automation. For example, a startup product may begin in a home or garage. It may grow until it needs external storage and processing, but the first system may only have a conveyor belt and carts. As supply and demand grow, the need for semi-automation grows too. Below are the three primary types of material handling in logistics.

1. Manual material handling

During this process, employees lift, carry, deliver, and unpack boxes and containers by hand. They may also use a hand trolley or a straight-line conveyor belt. Larger loads may be transported via a forklift, but unpacking is typically manual. This system of operation is labour-intensive and can create bottlenecks and processing delays.

Even with a light load, repeated bending, reaching, and lifting can strain your neck, back, and shoulders. The heavier or bulkier the load, the higher the injury risk. Either way, a manual system has a higher risk of accident, injury, and employee turnover. While a top option for startups, this method of handling is generic, and it isn't time-, labour-, or cost-efficient.

2. Semi-automated material handling

This refers to systems utilising forklifts, electric trolleys, and stationary, ceiling-, and forklift-mounted hoists, cranes, and lifting equipment. These systems eliminate drop risk, enable single-person lifting of bulky goods, and lift materials that weigh up to 240 kg. Semi-automation minimises bending, lifting, and straining by 80% or more. It can increase picking speed by two times or more depending on the types of materials you handle.

Lifting and gripping technology requires manual operation to attach, lift, reposition, and mount or stack. It is manually operated via ergonomic handles, automated push buttons, or joystick technology. Most units are operated from behind, which further decreases the risk of injury. This enables lifting deep into pallet racks and truck beds, and many options can be programmed to reach and position your highest racks. The vacuum-powered suction cups and material handling hooks can be customised to lift your unique product range effortlessly, and many cups and hooks are interchangeable for maximum versatility.

3.Fully automated material handling

Fully automated processes all but eliminate the need for manual labour, with machines and robots completing the majority of the work. For example, people may only be required to:

• Unload and load at the loading dock.
• Perform quality assurance inspections.
• Operate and monitor technology.

These advanced systems utilise automated assembly lines, multi-route automatic picking, and forklifts with built-in sensors. They process orders up to 100 times faster than humans, with a fraction of the labour costs of a semi-automated process. Some of the technology can even be operated remotely.

Full automation drastically reduces injury risk and product damage. The main roadblock is the large financial investment these systems require. Small to mid-sized operations may not have it.

Automation tools and technology

There is no one-size-fits-all solution, as your tools and technology must be tailored to your:

• Business type
• Product type
• Warehouse layout
• Ceiling height
• Order mix
• Order volume
• Compliance requirements
• And more

Let's dive into some of the most common products you will likely need.

Software

You are likely to utilise software, but if you haven't upgraded it in the last few years, it's time to consider your new options. The most robust software goes beyond inventory management to:

• Identifying warehouse bottlenecks.
• Automating maintenance alerts.
• Automating emergency and risk alerts.
• Advanced analytics for product forecasting.
• Advanced analytics for staffing.
• Real-time inventory and order tracking.
• And more.

Storage systems

Storage systems maximise space and organise your parts, supplies, and inventory. This might include any combination of:

• Pallet racks
• Drive-through racks
• Push-back racks
• Sliding racks
• Interlocking stacking frames
• Bins, drawers, and shelves
• Floor-to-ceiling mezzanines

Automated handling systems

Mapping out efficient material handling in logistics requires stationary units that work together to minimise manual movement. This might include any combination of:

• Conveyor systems made from belts, rollers, or flexible chains.
• Automated Storage and Retrieval Systems (AS/RS) that utilise cherry pickers or other shuttle systems for quick retrieval.
• Robotic delivery systems that automate moving products from one assembly line to the next, or from one area of operations to another.
• Automatic guided vehicles that use any combination of magnets, floor wires, vision sensors, or lasers to move heavy or bulky unit loads.

Industrial trucks

If your current volume doesn't warrant plant-wide conveyor systems, industrial trucks are used to unload, move, and load products. Even with conveyor systems, you'll require industrial trucks.

• Standard hand trucks, push carts, dollies, and box carts.
• Pallet jacks to lift and move full pallets.
• Manual or electric forklifts or pallet trucks to lift larger loads.
• Electric push trolleys that minimise the force required to move loads.

Bulk material handling

If you manage bulk raw materials, bulk handling systems optimise space and simplify handling.

• Hoppers are large funnels that direct loose materials into containers.
• Reclaimers are machines that pick up loose materials from the stockpile.
• Automated stackers move loose materials without hands-on intervention.
• Bucket elevators transport and store bulk items such as grain sacks.
• Grain elevators store and move grain safely and efficiently.
• Silos securely store and provide quick access to grains, coal, sawdust, food products, etc.
• Stackers are advanced forklifts explicitly designed for lifting and stacking heavy loads.

TAWI's semi-automated lifts, hoists, and crane systems

TAWI offers a curated mix of semi-automated tools to reduce physical lifting, straining, and bending. Our products are proven to improve safety, support cross-training, and reduce labour hours — while increasing production throughput.

1.Order picker forklifts

Order picker attachments fit any forklift or truck and use heavy-duty suction cups to lift from the top or sides of each box. Their features include:

• Compatible with any forklift or pallet jack.
• An articulating arm for optimal reach.
• Adjustable height that facilitates reaching deep into pallet racks.
• Support legs that provide extra stability.
• The ability to grip boxes from the top or the side.
• Lifting boxes of all sizes, up to 80 kg.
• An articulating arm that rotates 360 degrees for easy loading.
• Optional interchangeable lifting tools to meet your needs.

2.Vacuum lifters

Vacuum lifters utilise industrial-powered technology to lift, tilt, rotate, and load various goods without damage. They lift up to 270 kg with the use of interchangeable suction cups, which can be customised to your unique needs. Vacuum lifts can be ceiling- or floor-mounted, or mounted to your forklift or pallet jack, to lift:

• Boxes
• Taped boxes
• Plastic bags
• Glass sheets
• Plastic panels
• Wood panels
• Windows
• Food products
• Metal canisters
• Odd-shaped parts
• Carton boxes
• Wine boxes
• Blocks of meat
• Blocks of cheese
• Luggage
• And more

3.Cranes

Crane systems are ideal for servicing an entire assembly line or logistics unit. They also work well in areas that don’t need plant-wide mobility. Cranes can be securely mounted to the ceiling, roof beam, floor, or floor pillar. Some can be mounted to a forklift or a trolley that can be repositioned manually or by remote control.

Jib cranes are usually floor- or column-mounted. They have overhead arms that reach up to 6 meters. They can handle materials up to 125 kg. Our customisable overhead cranes have a bridge for long-distance lifting. Options include telescopic arms and low-ceiling cranes. They also support linear and non-linear production. Choose single or double girders. Aluminium cranes are used for goods up to 125 kg; steel cranes are used for loads up to 1,500 kg.

4.Hoists / air hoists

Chain or wire hoists may be your best option for ultimate precision, accuracy, and control. Hoists can be used for lifting various boxes and materials, and are ideal for large, heavy, and semi-flexible items such as bags. Some can be designed to lift multiple items at a time. Our chain hoists have an IP65 rating.This makes them suitable for outdoor use and harsh environments.You can control them remotely from a safe distance.They can lift up to 2,500 kg.The hook can rotate 360 degrees.

For swift, precise handling of lighter loads up to 120 kg, our high-speed wire hoists are the perfect choice—equipped with a single-hand joystick for grip control, they offer tilt and rotation and ensure secure load retention during unloading. Our vacuum-powered panel lifters use suction cups to lift up to 500 kg.They tilt 90 degrees, from vertical to horizontal, to grip and rotate large sheets and panels.

5.Container unloaders

Container unloaders empower your team to quickly and efficiently unload loose cargo from trucks and containers. These powerful unloaders are designed to decrease the strain on the body by 80% or more while optimising unloading times, turning many two-person jobs into one-person jobs. This includes telescopic-mounted unloaders above conveyor belts and mobile high-frequency unloaders that can be moved throughout your production area.