Material Handling: Pros and Cons to Evaluate
Material Handling: Pros and Cons to Evaluate
Material handling refers to the movement, storage, and protection of the products or materials that are used in a warehouse or industrial setting. These tasks are facilitated by material handling tools. These tools help relieve the strenuous hard-labor or heavy lifting that would be required to perform these tasks by hand. Material handling tools & equipment are important for increasing operational efficiency and preventing workplace injuries. Whether you need to store an item in a high up area, transport an item into a vehicle, or simply move an item from one area of the warehouse to another, there is likely a material handling tool for the job.
Types of Material Handling Equipment
Forklift
Forklifts are probably the most well-known piece of material handling equipment. The forklift is a gas, propane, or electric powered piece of industrial machinery used to lift/move equipment around a warehouse or job site.
| Pros | Cons |
| Can access pallets on ground & high places | Gas, propane, or electrical charge needed |
| Zero turn radius | Proper training and certification required |
| Little to no manual labor required to use | Expensive, approximately $20,000-$50,000 |
Pallet Jack
The pallet jack is another one of the most popular and commonly used pieces of material handling equipment. A pallet jack is a two-pronged manually powered forklift that is used to move pallets around the warehouse and into the backs of vehicles. They are an especially good fit for any company with a smaller warehouse in need of moving around smaller pallets, or pallets stored in tight spaces that cannot be accessed by forklifts. These are very common and can be found in most warehouses/industrial areas. Pallet jacks are available in a variety of sizes, but most typically come in either standard or narrow.
- Good for any regular sized pallets
- Zero turn radius, can be operated by a single person
- Load capacity 5500 lbs.
- Dimensions 27 x 48”
- Cost: $329.00-$369.00/Each
- Good for smaller, odd-sized, or skinnier pallets.
- Zero turn radius, can be operated by a single person
- Load capacity 5500 lbs.
- Dimensions 21 x 48”
- Cost: $340.00
The type of pallet jack you will need is primarily based on pallet size. However, it is important to consider the load capacity as well. Make sure you know the size of loads you will be handling before choosing the right pallet jack for you.
| Pros | Cons |
| Maneuverable in tight spaces | Can be used for pallets only |
| Can carry loads up to 5500lbs. | Require manual labor to move |
| No fuel or charge required to operate | Ground access only, cannot reach high places |
Dolly
Dollies are great for general purpose moving or storing. The dolly is a 4-wheeled piece of equipment with a flat platform where you can place the item that needs transported. Once in place, simply push/pull the item to where it needs to go. The amount of weight that can be carried on a dolly depends on the material and load capacity. Dollies are available in different materials ranging from strong metals to hardwood to plastic. They are a popular choice amongst movers & delivery drivers as they are great for moving household items such as furniture, cabinets, and refrigerators
- One of the most commonly used dollies
- Load capacity 1000 lbs.
- Skid proof wheels do not leave marks on the floor
- Dimensions 30 x 18 x 6 3/8”
- Cost: $45.00-$54.00/Each
| Pros | Cons |
| Items can be placed directly onto dolly, no pallet or additional flat surface needed | Can be hard to control with one person |
| Minimal training, no certification required | Labor required to load material onto the dolly |
| Fully rotating wheels, can move in any direction | Difficult to maneuver on rough surfaces or on inclines/declines |
Hand Truck
Hand trucks are a great, easy to load option for quickly moving items from one place to another. As opposed to the dolly, the hand truck is an L-shaped, 2-wheeled piece of equipment that stands upright. Hand trucks can easily be loaded by sliding underneath the object you need to transport without having the lift the object by hand. Once loaded, the hand truck is tilted backwards, allowing you to move the item.
| Pros | Cons |
| Easier to load than dollies | Requires physical labor |
| Can move multiple items stacked on top of each other at once | Requires coordination & balance to transport heavy items |
| Great for moving up/down ramps to load/unload trucks | No axel, wheels do not rotate or swivel |
- General purpose hand truck
- Dimensions 7.5” nose plate, 48” height
- Load capacity 500 lbs
- Cost: $189.00-$214.00/Each
Utility Carts
Utility carts are the perfect solution for anyone who is picking orders, loading multiple small items at once, or carrying smaller parcels. Like dollies and hand trucks, utility carts are made from different types of material. They are helpful if someone is compiling parts or pieces to put an order together. They are easy to use and are pushed by hand.
| Pros | Cons |
| Can carry several small items at once | Not made for carrying heavy objects |
| Fully rotating wheels | Need a hard/smooth surface to roll on |
| Features a top & bottom shelf | Not great for outdoors |
- Black polyurethane material
- Dimensions 34 x 17 x 31”
- Load capacity 500 lbs.
- Cost: $180-$190.00/Each
Material Handling Hazards & Injuries
While material handling equipment is designed to prevent injuries, injuries can result if the equipment is not used properly. While most manual material handling tools do not require certifications, it is still crucial for employers to be proactive in providing proper training for those who will be using the equipment. That means workers should understand to not exceed weight limits, be aware of their surroundings, and make sure loads are secure before moving so that it does not fall off and damage the object or the person handling the equipment. In a warehouse environment, it is important to keep areas clear and clean to avoid trip hazards. Most warehouses have OSHA regulations as well. It is important that those regulations are being met. Many businesses implement a “See Something, Say Something” policy to help stop the misuse of equipment before an accident or injury occurs.
Every employee, whether they are a direct user or not, needs to understand how material handling equipment is properly used. Misuse of material handling equipment present dangers to both the user and everyone else in the workplace.
Material handling tools are used for many reasons and in many different environments. If you would like to know what piece of material handling equipment is right for you, are interested in purchasing a piece of equipment, or have any questions at all, please talk to one of our product experts.