What is the pallet size? How many pallet locations do you need? How much throughput will you require? How many SKU will be kept in your ASRS?
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When I get a project, I always ask customer questions as this order. There is no doubt, pallet size is the basic point in ASRS design, which decides the racking structure, and pallet location is related with how big area will this ASRS need. Today I need to discuss about throughput.
About Throughput
Throughput means cargo inbound and outbound frequency. In other words, how many pallets inbound and outbound per hour in ASRS? I would like know such data from customer, 120 pph (pallets per hour) inbound 8 hr per day, 100 pph outbound 10 hr per day. The amount of inbound and outbound for a day should be almost the same, for if inbound is more than outbound, the ASRS will be full finally, if outbound is more than inbound, the ASRS will empty forever. Usually we take the peak throughput as our design target to make sure it can work at any time.
About Single Circle and Combine Circle
Single circle means stacker crane takes 1 pallet from inbound point and unload at defined location, then back to inbound point or stacker crane gets order from WMS to defined location take the pallet and go back to outbound point. It deals with 1 pallet operation in 1 circle.
Combined circle means stacker crane takes 1 pallet from inbound point and unload this pallet at defined location, then move to next defined location, taking the cargo and move to outbound point.
It deals with 2 pallet operation (1 inbound and 1outbound) in 1 circle.
Parameter Explains
Stacker Crane Travelling Path and Lifting Path
According to FEM 9.851 Performance data of SRMs: Cycle time, throughput calculation will use 2 point inside of ASRS. Point A(1/5L,2/3H) and point B(2/3L, 1/5H), L is racking length, H is distance from first layer bottom to top layer bottom.
Inbound and outbound Offset
Inbound point and outbound point are not on the same floor in some project. In our Hengshun Vinegar project, FG are palletize by robot hands and sent to ASRS by conveyor, its inbound point was installed on mezzanine floor. It effects stacker crane circle mode.
Max. SRM Travelling Velocity and Average Acceleration
Our HUADE brand stacker crane travelling speed range is from 120-160m/min and average acceleration is 0.3 to 0.5 m/s2. There are 2 situation when we calculate how long will stacker crane arrive at defined location in X direction (horizontal direction). Situation 1: The travelling path is not long enough, stacker crane cannot reach to max velocity before half point, when it passes half point, it will slow down and stop at defined location. Situation 2: The travelling path is long enough, stacker crane can reach the max velocity before half point. It will do uniform motion and then slow down until it arrives at the defined location.
Max. SRM Lifting Velocity and Average Acceleration
HUADE brand stacker crane lifting speed range is from 40-60m/min and average acceleration is 0.3 to 0.5 m/s2. Lifting calculation also should consider 2 situations, and method is the same as the travelling.
Fork Velocity, Travelling Path, Creeping and Position period
HUADA fork telescopic speed range is from 30-60m/min, full loaded speed and empty loaded speed will be different. Fork travelling path is equal to stroke length, and our fork need 3.28 seconds to finish creeping lift or down operation.
Responding Time
Every move of stacker crane follows orders from WMS, it need to analyze and finish these operations which need responding time. We suppose this period is 12 seconds in every circle.
Single Circle
We need to judge whether the stacker crane can reach Max. Velocity before half point in X direction, it calculation will go like following:
0.5*a*(Vmax/a)≥0.5*L/5, it is situation 1.
Stacker crane reach to Point A defined location in X-direction period calculation will go like following:
If 0.5*a*(Vmax/a)＜0.5*L/5, then it is situation 2. The calculation method will go like following:
Accelerated motion/Decelerated motion period:
T=Vx/ax
Uniform motion period:
S=0.5*ax* T2
Tu=(L/5-2S)/Vx
Tx= 2Ta+ Tu
We need to calculate the lifting period, the method is the same with travelling period. First, judge it is situation 1 or 2.
0.5*a*(Vmax/a)≥0.5*2H/3, it is situation 1.
Stacker crane reach to Point A defined location in Y-direction period calculation will go like following:
If 0.5*a*(Vy/ay)＜0.5*2L/3, then it is situation 2. The calculation method will go like following:
Accelerated motion/Decelerated motion period:
T=Vy/ay
Uniform motion period:
S=0.5*a* T2
Tu=(L/5-2S)/Vy
Ty= 2Ta+ Tu
Stacker crane does travelling and lifting at the same time, so we should compare Tx and Ty, and take the max one as stacker crane from O to A period in Y direction.
Fork velocities are different in empty and unloaded situations, also they have different acceleration. The calculation will goes like following:
T=Vze/aze
Uniform motion period:
S=0.5*a* T2
Tu=(L/5-2S)/Vz
Tze= 2Ta+ Tu
And Full load calculation method is the same.
Tz=Tze+Tzf+Tcr*2
Finally, Ta=Tx/Ty+Tzr+Tr, T=( Ta+ Tb)/2
Combined Circle
Ta and Tb calculation method is the same. The Period of Point A to Point B, we can called it Tab
Finally, T= Ta+ Tb +Tab+2*Tz+Tr
According to experience, the practical throughput is 80% of theoretical throughput. So we can do the rough calculation by this method.
All mechanical tools used to move, store, control, and protect materials throughout manufacturing, warehousing, distribution, and delivery are included under Material Handling Equipment (MHE).
Ever walked into a busy warehouse and wondered how thousands of items move so efficiently from shelf to shipping dock? The secret lies in what industry insiders call MHE, Material Handling Equipment.
From forklifts and pallet racking in a warehouse to conveyor belts in a distribution center, MHE forms the backbone of logistics.
Let’s see what MHE is, its history and functions, the different types of equipment, and how the right choices can boost your warehouse performance. Along the way, we’ll share examples and trends, plus tips on selecting and maintaining MHE.
Material Handling Equipment (MHE) refers to the mechanical tools and systems used to move, store, control, and protect goods and materials in production and distribution processes.
In other words, MHE is any machinery or device that handles materials rather than people. For example, a warehouse forklift that lifts and carries pallets is MHE, as are conveyor belts, storage racks, hoists, and even smart automated robots. Historically, material handling began with simple carts, hoists, and conveyors in early factories.
The modern forklift was invented in the early 20th century, revolutionizing warehousing and manufacturing. Since then, MHE has grown to include highly automated solutions like automated storage/retrieval systems (AS/RS) and robotics. The core functions of MHE are to move, store, control, and protect materials. In practice, this means:
Each function is essential. Without proper moving equipment, you’d spend hours manually walking items across the warehouse, while adequate storage equipment (like pallet racks) lets you stack inventory safely to maximize space. Together, these functions keep products flowing smoothly through the supply chain.
Different industries use different categories of MHE depending on needs. Common types of equipment include:
Transport Equipment: Machines that carry or move loads from place to place. This includes forklifts, pallet trucks (jacks), hand carts, conveyors, and automated guided vehicles (AGVs).
Forklifts are the workhorses of most warehouses, they lift pallets and load goods onto trucks. Conveyor belts and roller lines move boxes and packages along fixed paths between processes.
For example, a packaging conveyor will carry products from the packing station to shipping. Transport equipment is ideal when you need frequent, regular movement of materials across fixed or variable routes.
Examples & Avg. Prices in US dollars:
Positioning Equipment: Devices that handle materials at one location by lifting, tilting, or rotating them. Common examples are hoists, lift tables, cranes, turntables, and manipulators.
A scissor lift table raises pallets to waist height for ergonomic loading, and an overhead hoist lifts heavy engines onto a workbench. Positioning equipment enhances worker safety and precision: it improves productivity when materials must be aligned or fed into a process
As Wikipedia notes, these devices boost output and reduce injuries when frequent handling is needed.
Examples & Avg. Prices in US dollars:
Unit Load Formation Equipment: Tools and accessories that create or support a unit load, meaning a single manageable load from multiple items.
For example, dozens of boxes on a pallet become one unit for easy lifting and moving. Crates and bundling devices similarly keep items together so they don’t scatter during transport. By standardizing loads, unit load equipment simplifies automated handling and protects materials.
Examples & Avg. Prices in US dollars:
Storage Equipment: Systems used to hold inventory over time. This includes shelving, pallet racks, bins, mezzanines, and vertical carousels. Storage equipment is all about maximizing space and accessibility
For example, multi-tier racking lets you stack pallets in narrow aisles, saving floor space. Locking bins and shelving organize small parts, reducing search time. The design of storage (single vs. double-deep racks, automated lifts, etc.) involves trade-offs between handling speed and space utilization.
Well-planned storage gear will minimize travel time while fitting more goods in the same area.
Examples & Avg. Prices in US dollars:
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Engineered Systems: Complex, often computer-controlled systems that combine multiple equipment types into an automated solution.
The best-known example is an Automated Storage & Retrieval System (AS/RS): a network of high racks with cranes or shuttles that automatically store and retrieve pallets or totes.
Examples & Avg. Prices in US dollars:
Other examples include robotic picking systems, conveyor sorting lines, and sophisticated automated packing lines. These engineered systems “streamline and optimize material handling processes” with minimal human labor.
A modern distribution center might use robots to pick items and conveyors to sort packages, greatly boosting speed and accuracy.
High-speed engineered systems (above) like automated assembly lines and AS/RS combine conveyors, robotics, and controls to optimize material flow.
Each category of MHE plays a different role. Many facilities use a combination: e.g., a forklift (transport) loads pallets onto an AS/RS (engineered system), which then stores them on racks (storage).
MHE is used wherever physical goods are handled. Key applications include:
Warehouses and Distribution Centers: These facilities rely heavily on MHE to receive, sort, store, and ship products. Forklifts and pallet jacks move shipments to and from trucks. Pallet racks and shelving store inventory.
Automated conveyors and sorters can link packing areas to loading docks. In large warehouses, high-density storage (like pallet flow racks or AS/RS) minimizes space use. The result is faster order fulfillment and efficient inventory management.
Manufacturing Plants: On factory floors, MHE keeps production lines fed with parts and carries away finished goods.
Examples: Conveyor belts and roller conveyors move components between workstations; industrial robots and assembly-line pick-and-place units handle parts; overhead cranes and hoists lift heavy machinery or molds.
If an automotive plant might use conveyor-fed robotic arms to assemble parts, while forklift trucks supply pallets of raw materials to each station. Proper MHE ensures the plant runs without bottlenecks.
Retail and E-commerce Fulfillment: Retail backrooms and e-commerce warehouses use MHE to process customer orders quickly. Small pallet jacks or walkie stackers handle pallets of product. Conveyor sortation systems route packages to packing stations.
Automated guided vehicles (AGVs) or robots (like Kiva/Amazon robots) retrieve items for shipping. In fast-moving online distribution centers, MHE upgrades (e.g. adding pick-to-light systems or automated carts) allow hundreds of orders per hour with minimal errors.
Other Industries: Any facility that stores or moves goods, aerospace, pharmaceuticals, food and beverage, agriculture, etc., uses MHE.
For example, cold-storage warehouses use insulated platforms and frozen conveyors; hospitals use carts and elevators to handle supplies; Amazon distribution centers famously use robots and conveyors to pick millions of packages annually.
In each case, the right MHE equipment is chosen based on volume, item types and operational requirements. For instance, a high-throughput DC might invest in belt conveyors and automated sorters, while a small warehouse might get by with forklifts and static shelving. The goal is the same: speed up workflows and reduce manual labor.
Implementing proper material handling equipment offers clear advantages:
Improved Operational Efficiency: MHE automates manual tasks, cutting down travel time and increasing throughput. A forklift can move a 2,000-lb pallet in minutes instead of an hour by hand.
Conveyors run nonstop to eliminate walking back and forth. By streamlining flows, businesses fulfill more orders faster. Studies show that automated storage and conveyor systems can significantly boost picking speed and accuracy compared to all-manual methods.
Safety and Ergonomics: Using equipment reduces physical strain on workers. For example, lift tables bring loads up to waist height, avoiding bending injuries. OSHA mandates that forklift operators be trained and certified before use, and disciplined use of MHE prevents many accidents.
In fact, properly using forklifts and pallet jacks can prevent costly back injuries and crane accidents. Overall, MHE reduces the chance of workplace accidents when used correctly.
Better Inventory Control: MHE often comes with tracking or scanning systems that improve accuracy. Pallet racks and flow racks, combined with barcode or RFID systems, make locating stock easier.
This leads to fewer lost items and more reliable stock counts. Automated conveyors with sortation can ensure each item goes to the correct zone. The result is tighter inventory management and reduced shrinkage.
Cost Savings Over Time: While new MHE requires investment, it lowers labor and error costs long-term. Fewer workers are needed to move the same volume of goods, and automation reduces damage and spoilage.
For example, electric forklifts have lower fuel/maintenance costs than old diesel ones. And high-density storage saves on expensive warehouse space. Over the years, these savings yield a strong return on the MHE investment.
Scalability and Flexibility: Modern MHE systems (especially modular ones like conveyors and automated systems) can grow with your operation. Adding another conveyor line or extending racks is easier than hiring new staff.
Scalable MHE gives companies an edge during growth or seasonal surges. This agility is a competitive advantage in supply chain management.
MHE transforms warehouse operations by making them faster, safer, and more precise. Many industry surveys find that companies with advanced material handling gear report higher on-time delivery rates and lower accident rates. Implementing the right equipment is a key step toward a truly world-class warehouse.
Selecting the right MHE requires a deep view of your needs. Like:
Material Types & Volume
What are you handling? Heavy pallets, fragile cartons, bulk liquids? The weight, size, and nature of the product dictate the equipment. Very heavy loads need high-capacity forklifts or cranes, while delicate items might use conveyors with gentle handling.
Also, look into volume: large throughput (thousands of units/day) might justify conveyors or AGVs, while small volume might only need manual trucks.
Facility Layout & Space
Warehouse dimensions and configuration influence choices. High ceilings and narrow aisles may favor narrow-aisle forklifts or racking that reaches higher to maximize cubic space.
Limited floor area might push you toward vertical lifts or stacker cranes (AS/RS). Conversely, a wide open floor could use multiple forklift aisles. Walkways, dock locations, and building obstructions all factor in.
Budget & Return on Investment
New MHE can be expensive, so budget realistically. Compare the upfront cost to long-term savings. A cheap used forklift might cost less now, but could yield higher maintenance fees.
Also see financing or leasing options. Calculate ROI: Upgrading to faster pallet jacks might cut labor hours, paying back the cost in months.
Growth & Scalability
Plan for future needs. If you expect growth, choose systems that can expand. Modular conveyors, stackable shelving, and fleet expansions allow scaling.
Buying MHE that’s too specialized for today’s volumes could hinder future flexibility. It’s often better to start with modular or “future-proof” solutions if growth is anticipated.
Special Requirements
Some industries have unique needs. For example, food-grade warehouses may require washdown-capable equipment, and electronics fabs need ESD-safe handling tools.
Hazardous materials might demand explosion-proof forklifts. Temperature-controlled sites might need special motors. Identify any compliance or regulatory standards up front.
Operator Skills & Training
If skilled forklift drivers are scarce, maybe invest more in automation or simpler manual tools. Factor in training time and ease of use for each option. Some advanced systems have steep learning curves.
Consulting with experienced MHE suppliers like MDS Industrial can help match the right equipment to your specific scenario.
Proper maintenance and safety protocols are essential for MHE to function reliably:
Scheduled Maintenance: Follow manufacturer guidelines for inspections and servicing. For example, forklifts should get daily pre-shift checks (fluids, brakes, forks) and regular servicing per hours of use.
Conveyor lines and lift tables need periodic lubrication, belt checks, and safety inspections. A maintenance log helps track repairs and prevent breakdowns. Scheduled downtime for upkeep avoids costly emergency repairs that disrupt operations.
Operator Training & Certification: All MHE operators must be trained for their specific equipment. OSHA requires forklift drivers to be certified.
Proper training dramatically reduces accidents, a certified operator is less likely to tip a load or misuse controls. Even for conveyors and cranes, ensure staff know safe procedures (for example, lockout/tagout during maintenance). Continual training updates keep skills sharp.
Safety Practices: Enforce safe work rules. Use guardrails, safety mats, and warning lights around moving equipment. Ensure clear signage for forklift traffic and pedestrian zones. For lift platforms and bins, enforce proper loading limits to avoid collapse. Always keep load paths unobstructed and forklift attachments properly secured.
Regulatory Compliance: Adhere to all relevant regulations and standards. In the U.S., OSHA’s “Powered Industrial Trucks” standard (29 CFR .178) covers forklift safety and training. Many states have additional rules.
Maintenance practices may be guided by ISO or ANSI standards for conveyors and lifts. Staying compliant not only keeps workers safe but also avoids fines.
Regular Inspections: Beyond operator checks, have periodic professional inspections. For example, get conveyors and racks certified safe every year. Replace worn parts immediately (e.g., cracked pallet fork or damaged belt). Even well-built systems can fail if neglected, so proactive inspection is key.
When MHE is well-maintained and operators are properly trained, warehouses see fewer shutdowns, longer equipment life, and much lower accident rates.
It pays off to invest in safety: a single forklift accident can cost tens of thousands in injuries and downtime. MDS Industrial offers maintenance services and safety training programs to help companies keep their equipment in top condition.
The material handling industry is evolving rapidly. Like:
Automation and Robotics: More warehouses are adopting robotic systems and AS/RS solutions. Automated Guided Vehicles (AGVs) and autonomous mobile robots (AMRs) navigate factories to move loads without human drivers.
Robotic palletizers, robotic picking arms, and automated conveyors are streamlining operations. As noted in industry research, engineered systems now “optimize material handling processes” by automating storage and retrieval.
Smart MHE (IoT Integration): The Internet of Things (IoT) is coming to warehouses. Modern equipment often includes sensors and telematics.
For example, smart forklifts can report their usage, location, and maintenance needs in real time. Conveyors can automatically adjust speed based on load using sensors.
Warehouse Management Systems (WMS) integrate with MHE to give live inventory and movement data. This connectivity allows predictive maintenance (fixing a conveyor belt before it breaks) and better asset utilization. Gartner reports that logistics companies adopting IoT-enabled handling equipment see dramatic improvements in uptime and efficiency.
Energy Efficiency and Sustainability: As companies pursue “green” operations, MHE is following suit. Battery-electric forklifts with fast charging are replacing diesel, reducing fuel costs and emissions. Regenerative braking and variable-speed drives make conveyors more efficient. Some firms even use solar panels on warehouse roofs to power MHE. Sustainable design, like lighter-weight racks made from recycled materials, is also emerging. In sum, energy-efficient MHE is reducing carbon footprints and operating costs.
Advanced Materials and Add-ons: New materials (like composite pallets) and attachments improve performance. For example, collapsible pallets save space on return trips, and custom forklift attachments (rotators, carpet pole, drum clamps) let one truck do specialized jobs. These innovations give companies more flexibility for unique loads.
Real-world examples show how MHE upgrades drive results:
A prominent e-commerce retailer integrated automated sortation systems to streamline their order fulfillment process. By implementing high-speed conveyors equipped with barcode scanners and chute diverts, the warehouse significantly improved its parcel sorting capabilities (AutoStore).
This automation enabled the facility to handle peak holiday order volumes more efficiently, reducing reliance on manual labor and enhancing overall productivity.
An automotive parts manufacturer adopted an Automated Storage and Retrieval System (AS/RS) to manage engine component storage. This system utilized high-density vertical storage and automated shuttles for precise part retrieval (Daifuku).
The implementation led to a 25% improvement in picking accuracy and a 40% increase in rack space utilization, resulting in a 15% boost in assembly line uptime due to timely part deliveries.
A major grocery retailer transitioned from diesel-powered forklifts to electric models and introduced multi-tier racking systems in their warehouses (Cat Lift Trucks).
The electric forklifts provided a quieter and cleaner operating environment, eliminating diesel fumes. The new racking system increased storage capacity by 20%, and the ergonomic design of the trucks reduced employee fatigue. The investment achieved ROI in under two years through energy savings and lower maintenance costs.
A third-party logistics (3PL) provider upgraded its distribution center by implementing RF-guided pallet trucks and voice-directed picking systems (MWPVL International).
This technology enabled warehouse staff to pick orders 30% faster with fewer errors. The improvements in speed and accuracy attracted new clients requiring rapid and precise order fulfillment, boosting the company’s revenue.
These cases show a pattern: strategic MHE investments lead to significant efficiency gains. While results vary, companies often see double-digit improvements in throughput, accuracy, or cost savings after adopting modern material handling solutions.
MDS Industrial is your partner in MHE solutions. We offer a full range of equipment and services to optimize your warehouse or facility:
Evaluate your material handling needs today. Talk to MDS Industrial’s specialists about tailored solutions that fit your budget and growth plans. With MDS, you get not just equipment but expert guidance — a winning combination for warehouse and supply chain success.
Material Handling Equipment is the backbone of any efficient warehouse or supply chain operation. By moving, storing, and protecting goods effectively, MHE unlocks productivity gains and safety improvements. In a competitive market with rising e-commerce demands, investing in the right forklifts, conveyors, racks, and automated systems gives you a real advantage. We covered what MHE is, the types of equipment available, its applications and benefits, and tips on choosing, maintaining, and upgrading your systems.
The key takeaway: Don’t delay evaluating your material handling strategy. Proactively upgrading equipment and training staff pays off in faster throughput, fewer injuries, and lower long-term costs. For a competitive edge, work with experts like MDS Industrial. We can help you audit your current setup, recommend the best MHE equipment, and implement custom solutions tailored to your needs. Explore MDS Industrial’s warehouse solutions today and take the first step towards a smarter, more efficient supply chain.
Sources: Industry definitions and guidelines were referenced from authoritative sources: en.wikipedia.org , osha.gov
These resources provide technical background on MHE categories and safety standards, reinforcing best practices mentioned above.
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