Efficient movement of material is a key component of modern industrial operations. In environments where time is money and safety is non-negotiable, the ability to transport, store, and access materials quickly and securely defines whether a facility runs smoothly or suffers costly downtime.
According to the U.S. Bureau of Labor Statistics, nearly 20% of all workplace injuries occur in warehousing and logistics, many of which are tied directly to poor material handling practices. In addition, the staggering operational delays are estimated to cost manufacturers an average of $250,000 per hour. It’s clear why investing in the right material handling equipment isn’t optional – it’s fundamental.
From assembly plants and distribution hubs to construction sites and agricultural operations, material handling equipment plays a central role in streamlining throughput, maintaining inventory accuracy, and reducing risks.
But what is material handling equipment able to do? How do you determine which tools are best for your needs?
This guide examines the four primary types of material handling equipment, outlines their uses, and breaks down the factors influencing smart equipment selection.
What Is Material Handling Equipment?
Material handling equipment encompasses any mechanical, automated, or manual tool designed to assist in moving, storing, protecting, and controlling goods throughout the manufacturing, warehousing, and distribution processes. This can include everything from storage racks and conveyors to forklifts, hoppers, and advanced robotic systems.
So, what is material handling equipment in operational terms? It’s the structured approach to controlling movement, reducing waste, improving accuracy, and enhancing safety. Whether that’s through the use of forklifts, conveyors, robotic systems, or OSHA-compliant man baskets, this equipment facilitates safe and streamlined movement at scale.
The 4 Primary Types of Material Handling Equipment
Material handling types fall into four core categories:
- Storage and Handling Equipment
- Industrial Trucks
- Bulk Material Handling Equipment
- Engineered Systems
Each category addresses a different stage in the material movement lifecycle. Let’s explore how each type of material handling equipment works and where they fit into your operation.
- Storage and Handling Equipment
Storage and handling equipment is designed to hold materials while they await the next step in production or delivery. These static systems are foundational for maintaining order and maximizing space utilization, especially in high-density environments.
The right storage system doesn’t just keep materials organized. It makes them easy to access without creating unnecessary risk. When that access involves elevation, such as reaching mezzanines or high pallet racks, the need for OSHA-compliant man baskets and reliable fall protection becomes even more critical.
Common examples of storage and handling equipment include the following:
- Pallet Racks: Vertical racks for holding palletized materials
- Shelves and Bins: For smaller items and high-frequency use materials
- Mezzanines: Semi-permanent, elevated platforms that double the available workspace
- Stacking Frames: Interlocking structures that enable vertical stacking without product damage
From a safety perspective, storage systems must be compatible with your fleet of material handling equipment, so there are no workflow disruptions or compromises in load integrity. This depends on whether you’re using forklifts, order pickers, or walkie stackers.
- Industrial Trucks
This category includes motorized and manual trucks that transport materials from one point to another within a facility or across a job site. They’re the most common material handling types used in warehouses and construction zones.
Notable types of industrial trucks include:
- Forklifts: Versatile and powerful, capable of lifting from 3,000 lbs to 30,000 lbs
- Order Pickers: Ideal for warehouses with tall storage systems
- Pallet Jacks: Manual or electric tools for moving palletized loads
- Walkie Stackers and Side Loaders: Specialized for tight spaces and narrow aisles
- Platform Trucks: Used in assembly or shipping areas for small to medium loads
Each truck must be paired with the right attachment and load type, and operators must be trained in both machine operation and safety protocols. For environments that require elevation, like installing piping or overhead systems, combining industrial trucks with certified man baskets can ensure that personnel are lifted safely.
Here, the question “What is material handling equipment?” becomes more than a question of utility as it evolves into a matter of job site safety. Choosing the wrong truck or attachment can result in collisions, dropped loads, or falls from heights.
- Bulk Material Handling Equipment
Handling granular or loose materials such as sand, grain, ore, or coal presents unique challenges. Bulk material handling equipment is engineered specifically for volume, flow control, and containment.
This equipment is often used in outdoor or semi-outdoor settings, where environmental conditions like dust, moisture, and uneven terrain must be factored into the design. Operators working on hoppers or near elevated platforms must be protected using engineered fall prevention systems, including man baskets rated for overhead tasks.
For facilities that require frequent elevation changes, it’s critical that bulk material handling equipment is compatible with overhead lifting gear and that all rigging, including baskets, complies with ANSI A92.2 and OSHA 1926.453.
This level of compliance helps prevent serious accidents caused by equipment failure or unsafe lifting practices. It also reinforces a culture of safety on the job site, where workers can focus on the task at hand, knowing the gear supporting them meets the highest industry standards.
Here are some examples of common bulk material handling equipment used in industrial operations:
- Conveyors: Efficient horizontal or inclined movement of bulk goods
- Bucket Elevators: Move bulk materials vertically in enclosed systems
- Hoppers and Silos: Provide large-volume storage and controlled discharge
- Stackers and Reclaimers: Manage large stockpiles in mining or agriculture.
- Dump Trucks and Cranes: Transport and lift bulk loads in outdoor applications
- Engineered Systems
When automation is required at scale, engineered systems deliver consistent performance with minimal manual input. These are complex systems built around custom requirements, integrating robotics, storage, and transport systems into a single, efficient flow.
Common examples include:
- Automated Storage and Retrieval Systems (AS/RS): Computer-controlled systems for precisely placing and retrieving inventory
- Automated Guided Vehicles (AGVs): Self-navigating vehicles that deliver materials without human input
- Autonomous Mobile Robots (AMRs): These are more flexible than AGVs and can adapt routes on the fly
- Sortation Systems: Automatically direct packages or goods to designated locations using barcodes or RFID
- Palletizers: Automatically stack goods onto pallets for shipping or storage
Engineered systems dramatically improve throughput but require careful planning, particularly with safety in mind. If human operators must interface with these systems at elevated points during maintenance or troubleshooting, man baskets certified for the equipment must be used to ensure stable and secure access while minimizing the risk of falls or mechanical failure.
This is where the intersection between automation and human oversight becomes most important. Despite the increasing use of robotics, personnel safety remains paramount. Rigorous safety training, including certified man basket safety training, ensures workers are properly equipped when accessing overhead automation systems.
Choosing the Right Equipment
Selecting the correct material handling equipment isn’t a one-size-fits-all decision. It’s a strategic move that affects everything from daily productivity to long-term safety. The right fit depends on how your facility runs, the materials you’re moving, and the risks you’re trying to avoid.
Here are the key factors to consider:
Material Characteristics
Size, shape, weight, and fragility will determine the appropriate tool. Palletized goods may work with forklifts, but irregular or fragile items may require custom racking or robotic systems. For bulk items like grain or sand, hoppers, and conveyors, ensure efficient transfer while reducing manual handling risks.
Facility Layout
Ceiling height, aisle width, and load-bearing capacity all affect your equipment options. Warehouses with high ceilings can benefit from mezzanines and vertical lift systems. At the same time, tight aisles may require narrow forklifts or walkie stackers. If elevated access is necessary, ensure your team uses OSHA-compliant lifting platforms and man baskets.
Operational Volume and Throughput
Facilities processing high volumes need automation or high-capacity trucks. For example, if you’re moving thousands of pallets per week, automated sortation systems and AGVs may offer the return on investment (ROI) you need. Lower-volume operations may benefit more from manual equipment with a lower upfront cost.
Labor vs. Automation
Labor shortages and rising costs have increased the demand for automation. However, full automation isn’t always practical. A blended model, where machines handle repetitive tasks and workers oversee safety and exceptions, is often the most efficient. This also minimizes the risk of human injury in repetitive or hazardous environments.
Safety Requirements
This includes both regulatory and operational safety. OSHA and ANSI guidelines dictate how equipment should be used, especially when working at heights or with hazardous materials. Integrating certified man baskets, safety harnesses, and training programs into your operation can mitigate legal risks and protect your team.
Scalability and Maintenance
Choose equipment that can scale with your operation. Modular systems, flexible storage options, and automated tools that can be upgraded ensure long-term value. Equally important is ongoing maintenance for man baskets and industrial trucks to remain safe and compliant.
Invest in Performance and Protection With Lakeshore Industrial
The right material handling equipment is more than a cost. It’s a long-term investment in your facility’s productivity and your team’s safety. When it comes to critical decisions like these, you need a partner who understands what’s at stake.
At Lakeshore Industrial, we help decision-makers across manufacturing, warehousing, and construction secure the equipment that meets today’s demands and tomorrow’s challenges. Our safety-rated man baskets, rigging gear, and material handling solutions are built with precision, tested for compliance, and trusted across industries.
Contact Lakeshore Industrial today to find the right material handling equipment for your facility.