Types of Material Handling Equipment: Understanding the Essentials

May 19, 2025

Material handling is the cornerstone of efficient operations in warehouses, manufacturing plants, construction sites, and distribution centers. Whether moving pallets of product across a facility or transporting raw materials to a work cell, the tools and systems used to manage materials directly affect safety, productivity, and operational cost.

In this guide, we explore the types of material handling equipment, breaking them down into their core categories, usage scenarios, and value to businesses of all sizes. Whether you’re a facility manager optimizing your workflow or a business owner evaluating equipment investments, understanding these types is crucial to making informed, impactful decisions.

But before diving into the various types, let’s first touch on the foundational concept that ties them all together.

What Is Material Handling Equipment?

Material handling equipment, or MHE, includes machines and tools that help move, store, control, and protect materials. These tools are used in many places—factories, warehouses, shipping centers, and even disposal areas. Without them, moving items around would take longer and be more dangerous. They help workers stay safe, reduce how much physical work is needed, and make everything more efficient. That means saving time and money.

Here’s what MHE is used for:

  • Moving things from place to place. Think forklifts that carry pallets, conveyors that move boxes non-stop, or AGVs—robots that drive themselves without help.
  • Keeping items in storage until they’re needed. Pallet racks, tall shelves, mezzanines, and even machines that spin items around in tight spaces help organize things and save room.
  • Protecting items while they’re being moved. Breakable or dangerous stuff needs special care. That’s where padded containers, leak-proof pallets, and temperature-controlled boxes come in.
  • Controlling how things move through a process. Robots, smart sorting machines, and systems that follow exact instructions all work together to keep everything running smoothly.

Knowing how this equipment works is key if you deal with logistics, supply chains, or industrial operations. It doesn’t just move stuff—it helps people work better, stay safe, and follow the rules. It even makes it easier for companies to grow.

If you’re just learning about material handling, check out our beginner-friendly guide: What Is Material Handling and Its Benefits. It’s a great place to start and will help you understand how this gear boosts efficiency and supports long-term success.

Why Understanding Types of Material Handling Equipment Matters

Knowing the different kinds of material handling equipment really matters. It’s not just technical—it affects your business in big ways.

  • Staying Safe: Using the right gear makes the job safer. A pallet jack can’t replace a forklift when heavy lifting is needed. That mismatch leads to slow work—and real danger. Pick the proper tool, and you reduce accidents. Plus, it keeps you in line with safety rules like OSHA’s.
  • Getting More Done: The right equipment speeds things up. Think conveyors for moving tons of packages or AGVs that handle repeat tasks. Less manual work. Faster results. Better use of space. It’s all connected, and when it clicks, the whole operation runs smoother.
  • Saving Money: Buy smart, not big. If you know what the gear can do, you won’t waste money on things you don’t need—or worse, underperforming tools. Each piece should match your actual workload. That’s how you stretch your dollars and get more value from your investment.
  • Following the Rules: Some materials need special treatment. Flammable goods. Medicine. Food. They can’t be handled like anything else. You’ll need gear like explosion-proof lifts or cold storage units. These choices keep you on the right side of industry rules—and out of trouble.

Knowing all this gives you power. It’s how you choose better tools, stay safe, work faster, and keep growing. Whether you’re fixing last-mile delivery, cutting product damage, or getting ready to expand—understanding your equipment is the first step.

The Four Main Categories of Material Handling Equipment

Material handling tools are typically grouped into four primary categories. Each category plays a unique role in the movement, storage, or control of goods and materials.

1. Storage and Handling Equipment

Storage and handling equipment is what keeps materials in place when they’re not moving. It might not grab attention, but it’s key to how warehouses run. Without it, things would be chaotic. It helps keep products safe, makes better use of space, and supports smarter ways to manage inventory.

These tools form the base of a strong supply chain. They help with everything from saving space to staying on top of safety rules. If you pick the right gear, you can cut costs, move things faster, and make different inventory systems work—like FIFO, LIFO, or JIT. It all adds up.

Let’s look at a few examples.

  • Pallet racks: Strong metal frames. Stack goods up high. Good for when you need to store a lot and still get to things fast. Warehouses love them.
  • Shelving units: Think flexible. Great for smaller items. Handy in factories and backrooms. You can adjust them, add on more, and use them where pallets don’t fit.
  • Bins and containers: Small, simple, but powerful. They hold tiny parts or products with lots of variety. Add labels, maybe color-code them—boom, faster and more accurate picking.
  • Mezzanines: Not a storage rack, but a full new level—literally. Built above the ground, they turn empty air into usable space. Want to avoid adding a new building? Mezzanines can do the trick.

So, why care?

Because the right setup saves time. It cuts down on unnecessary movement. It keeps stuff from breaking. In places that rely on robots or need to handle lots of products, smart storage keeps the whole system going. It’s also safer for the people working there.

Picture this: an e-commerce warehouse. It’s busy. Fast. Every second counts. Workers use adjustable shelves and clear bins with labels. They grab items fast, make fewer mistakes, and get more done. Orders go out quicker. Costs drop. Everyone wins.

2. Industrial Trucks

Industrial trucks help move materials. They’re used in places like warehouses, factories, and loading docks. Some use engines. Others don’t. They carry loads from one spot to another. Each truck type does something different. Some are small and easy to steer. Others are big and strong. These trucks make work faster and help people avoid heavy lifting.

Types of Industrial Trucks:
  • Forklifts: Forklifts lift and carry heavy stuff. You see them everywhere—warehouses, outdoor sites, you name it. There are different types:
    • Counterbalance forklifts
    • Reach trucks
    • Rough terrain forklifts 
  • Pallet Jacks (Manual & Electric): These move pallets. Manual jacks are cheap and easy to use. Electric ones do more work with less effort. They’re great for short trips inside buildings.
  • Order Pickers: Need to grab items from high shelves? These are your go-to. They lift you and the load. Fast, accurate, and perfect for big warehouses or online stores.
  • Platform Trucks: Think of a flatbed on wheels. These move stuff that isn’t on a pallet. Simple. Handy. Good for smaller tasks or moving things around a single room or section.
  • Tow Tractors: You’ll see these at airports. They pull many carts at once. They save time when moving lots of goods over long paths.
Advantages:
  • Faster movement inside buildings: These trucks make it quick and easy to move stuff around.
  • Less lifting for people: They do the heavy work. That means fewer injuries and happier teams.
  • More ways to move items: Go up. Go sideways. Go wherever you need to. These trucks adapt.
Key Considerations:
  • Training is a must: Forklifts and electric jacks aren’t toys. Operators need training. Rules vary, but OSHA sets the bar in the U.S.
  • Match the truck to the space: Small aisles? Go with a narrow truck. Indoors? Electric is cleaner. Outdoors? Diesel might work better.
  • Look at the big picture: Trucks need care—repairs, parts, and power. All of it adds up. Know the costs before you commit.
3. Bulk Material Handling Equipment

Bulk material handling equipment moves large amounts of loose materials. These could be powders, grains, chunks, or other odd-shaped stuff. The goal? Keep everything flowing—fast and smooth. Unlike machines made to move one item at a time, these systems deal with volume. They’re built for speed, steady flow, and lots of it. Big industries rely on them when there’s a lot to move, and time is tight.

Key Equipment Types and What They Do
  • Conveyor Belts: These are long belts that carry materials from one place to another. They move things straight or uphill. Simple, but powerful. Need special features? Add cleats, make them heatproof, or reduce static. It depends on the material.
  • Hoppers and Silos: Hoppers let stuff flow out at a controlled rate. Silos hold things longer. Both are tall containers. To stop clogs, they sometimes shake or blow air inside. That keeps the material moving.
  • Bucket Elevators: These lift things straight up. Buckets scoop up powders or grains and carry them high. They don’t spill much. They also don’t take up much space. Great for feed mills or chemical plants.
  • Screw Conveyors: A spinning screw inside a pipe moves materials along. It’s closed off, so it’s clean and precise. Works well with rough or hot materials. Think cement or flour.
  • Stackers and Reclaimers: In big outdoor areas, stackers pile stuff up—like coal or ore. Reclaimers take it back when needed. Today, many use sensors and radar to be more exact and fast.
Industries That Use These Systems
  • Agriculture – Grain and feed flow fast through hoppers and elevators. Corn, soybeans, wheat—big quantities, no problem.
  • Food & Beverage – Flour, sugar, cocoa move in closed tubes. Keeps things clean and steady.
  • Mining and Quarrying – Moving rocks and ore needs tough, steady gear. Conveyors and hoppers handle it all.
  • Chemical and Pharma – Powders and pellets need clean handling. Closed systems protect workers and products.
  • Construction Materials – Cement, gravel, sand—they’re rough. These systems are built to last in harsh spots.

These systems keep industries running. They save time. Cut down on waste. Lower the need for hands-on work. Best of all, they’re designed to match what you’re moving—dense, fine, sticky, or dusty. Smart design boosts safety and keeps everything flowing just right.

4. Automated Systems and Handling Solutions

As supply chains get more demanding, businesses are turning to automated systems. These tools help move, store, and manage materials. They make work faster, safer, and more reliable. Plus, they let companies grow without needing tons more people or space.

What Are Automated Handling Systems?

These systems combine machines, robots, and smart software. Together, they handle how stuff moves around a warehouse or factory. Some are fully automatic. Others work with people. These tools use things like AI, sensors, and cameras to work fast and accurately.

Key System Types and Functions
  • Automated Storage and Retrieval Systems (AS/RS): These systems stack and pick items using robotic cranes or shuttles. They save space, cut down mistakes, and speed up order times. You’ll see them in places like cold storage warehouses or big distribution centers.
  • Automated Guided Vehicles (AGVs): AGVs are small, self-driving machines. They follow paths marked by wires, magnets, or lasers. They’re great for moving items over and over, safely and on time—without forklifts.
  • Conveyor and Sortation Systems: Conveyors carry products quickly. Sorters use sensors to direct items where they need to go. They’re perfect for big operations, like online stores or mail centers.
  • Robotic Picking Arms:These robotic arms see and grab items. They move fast and work with lots of different product types. You’ll find them in clothing warehouses and drug companies.
  • Warehouse Control Systems (WCS): This is the brain of the system. It connects all the machines and makes sure everything runs smoothly. It helps fix problems and keeps the warehouse efficient.
Core Advantages of Automation
  • Workforce Optimization: Automation means fewer people doing the same repetitive jobs. It’s helpful when labor is hard to find or too costly. People can instead focus on monitoring or solving problems.
  • Enhanced Speed and Accuracy: Machines don’t get tired. They follow instructions exactly. That means faster service, fewer mistakes, and happier customers.
  • Scalable Data Intelligence: These systems gather and share data in real time. That helps managers make better, faster decisions. They can see where things slow down—and fix it.
Considerations and Limitations
  • Capital Investment: These systems cost a lot at the start. Equipment, design, and upgrades add up. But over time, they often save more money than they cost.
  • Maintenance Complexity: High-tech machines need expert care. If something breaks and there’s no one to fix it, work can stop. That’s why planning ahead matters.
Ideal Applications

Automated systems work best in fast-moving, high-demand places. These include:

  • Third-party logistics (3PL) providers
  • Big company distribution hubs
  • Factories with lots of product types
  • Cold storage, pharma, and food warehouses
  • E-commerce fulfillment centers

The global material handling equipment market was valued at $239.3 billion in 2024 and is projected to grow to $390.88 billion by 2032, exhibiting a CAGR of 6.4% during the forecast period. This growth is driven by factors such as the expansion of e-commerce, increasing demand for automation, and advancements in technology.

Source: Fortune Business Insights

Hybrid Material Handling Solutions: Merging Manual with Automation

Not every company needs full automation. In fact, many don’t. Smaller businesses especially can benefit from a mix of human work and smart machines. This mix—called a hybrid system—helps improve work, grow operations, and stay flexible. All without huge spending or major changes.

Examples of Hybrid Systems:
  • Semi-Automated Pallet Wrappers: A person puts the pallet on a turntable. Then, the machine wraps it. The film is tight and even. Less lifting for workers. Faster wrapping. Safer and more efficient shipping. Easy win.
  • Pick-to-Light and Put-to-Light Systems: These systems use lights. Lights tell workers where to go. What to pick. Or where to place items. It’s fast. It’s clear. Fewer mistakes. New staff learn quickly. Tech that helps, not replaces.
  • Mobile Workstations: Workers move around with tools. They scan. They type. They print. No need to run back and forth to a desk. Saves time. Speeds up updates. Keeps track of stock in real time.
Why Hybrid Systems Work:

Hybrid setups aren’t a step down. They’re smart. Businesses can choose what to automate. Fix problem spots first. Don’t overhaul everything at once. It’s flexible. It fits tight budgets. It works with old systems.

These systems also grow with you. Need more tech later? Add it. Jobs also get better—less boring, less heavy work. People handle the tough calls. Machines do the grunt work. It’s smart. It’s balanced. It’s both human and machine—working together.

Factors to Consider When Choosing Material Handling Equipment

Choosing the right material handling equipment really matters. It affects how fast things move, how safe the workplace is, and how much money you make in the long run. You’re not just picking a machine—you’re choosing a system that fits your workflow, budget, and goals.

What are you moving?

That’s the first thing to ask. Are the materials soft? Fragile? Heavy? Liquid? Maybe hot or cold sensitive?

Also: are they packed in boxes, loose, or shaped weird?

Examples:

  • Boxes or pallets? Go with forklifts or pallet jacks.
  • Loose stuff like grain or powder? Try augers or pneumatic conveyors.
  • Fragile or pricey goods? Use soft bins or robotic arms that handle gently.

When the tool matches the job, things break less, safety rules are followed, and the whole process flows better.

How often are you moving things?

If it’s all day, every day—go automated.

Conveyor belts. AGVs. AMRs. These reduce strain and speed things up.

Not moving stuff as often? Then maybe just use dollies, carts, or a hand truck.

The idea is simple: cut delays, cut exhaustion, keep moving.

How far and which way?

Moving up? You’ll need lifts or freight elevators.

Moving far on a flat floor? Go for AGVs or conveyors.

Just moving across a short space? A pallet jack or cart should do.

Also think about curves, slopes, bumpy floors. Pick the wrong gear and things can get messy—slowdowns, damage, or even accidents.

Who’s using the equipment?

Think about your team. Can they handle complex machines? Do they need lots of training? Are they experienced or new?

If the team isn’t tech-savvy, go simple. Easy tools mean less training and fewer mistakes.

But if your crew knows their stuff? Then maybe invest in something more advanced.

Got enough space?

Space can be tight—especially in older or smaller warehouses.

  • Small space? Use narrow forklifts or vertical carousels.
  • Open layout? Go flexible—modular systems or equipment that moves around.

Before you buy anything, check your layout. You don’t want a traffic jam on your warehouse floor.

What does it really cost?

The price tag is just the start. Look deeper—how often will it need fixing? Is it energy-efficient? How long will it last? How much downtime does it cause?

A machine that costs more upfront might save you more in the end. Some high-end systems have smart maintenance tools. They break down less, save on labor, and keep things running.

Sometimes, leasing might actually make more sense than buying.

Emerging Trends in Material Handling Equipment

The world of material handling is evolving rapidly, propelled by advancements in automation, data analytics, and sustainability. Staying ahead of these trends is essential for businesses looking to optimize operations and future-proof their facilities.

Integration with Warehouse Management Systems (WMS)

Material handling gear isn’t working alone anymore. It’s part of the whole digital warehouse picture now. Smart forklifts, robot arms, and automated systems are built to talk directly to WMS software.

This means:

  • You can see your inventory in real time, across all parts of the warehouse.
  • AI helps predict what you’ll need and when you’ll need it.
  • Tasks get sent automatically to the right people—or machines.

What you get: fewer mistakes, faster operations, better decisions. It’s logistics with brains.

IoT and Smart Sensor Deployment

IoT—short for Internet of Things—is changing how we keep track of our machines. Sensors are now tucked into all kinds of equipment: pallet jacks, conveyor belts, you name it. And they’re always sending data.

You’ll benefit from:

  • Alerts before something breaks down. No more surprise downtime.
  • Real-time tracking using GPS and RFID.
  • Monitors that check conditions, great for sensitive products.

Dashboards turn all that info into actions. Instead of guessing, you’ll know what to do. Fast.

Sustainability and Energy-Efficient Innovations

Green tech isn’t optional anymore. Governments care. Customers care. Investors care. So, companies are getting serious about eco-friendly equipment.

Here’s what’s showing up:

  • Electric forklifts—no gas, no emissions.
  • Energy-saving motors that power conveyors.
  • Reusable or compostable packaging built into automated lines.

Bonus: Going green often saves money. And it helps with ESG scores, which matter to people watching your brand.

Human-Robot Collaboration (Cobots)

Cobots are a big deal. These are robots that don’t need to be locked in cages. They’re made to work safely right next to people.

They’re helping with:

  • Picking and packing—faster, fewer errors.
  • Bringing items to workers instead of the other way around.
  • Switching tasks on the fly when things get busy.

Perfect for mid-sized operations. Full automation might be too much, but a cobot gives you a flexible, helpful boost.

Scalability Through Modular and Flexible Systems

Warehouses used to be set in stone. Not anymore. Now it’s all about building systems that grow and shift with your needs.

Some cool examples:

  • Conveyor belts that can be extended when you get more SKUs.
  • Racking you can reconfigure depending on the type of product.
  • AGVs (automated vehicles) that map new routes without changing your layout.

You grow, they adapt. No need to tear everything down and start over.

Safety Considerations in Material Handling

Speed matters. So does getting the job done. But safety? That’s what keeps everything running long-term. If safety slips, things break down. People get hurt. Work slows. Lawsuits show up. It’s a mess no one wants.

Key Safety Protocols That Protect People and Profits:
  • Comprehensive Operator Training: Anyone using machines—forklifts, jacks, conveyors, AGVs—needs real training. Not just once. Regularly. They should know what loads they can handle, how far they need to brake, how to turn safely, and what to do in a crisis. Training cuts down accidents. Fewer mistakes. Less damage.
  • Routine Equipment Inspections and Maintenance: Machines fail. When they do, people can get hurt. That’s why checking them often is critical. Do it every day. Then every week. Then every month. Look at brakes. Hydraulics. Wheels. Sensors. Beeps and alarms too. If it’s smart tech, set up alerts to remind you. Prevention beats repair.
  • Ergonomic Considerations in Tool and Process Design: Manual work isn’t going away. That’s why ergonomics is a big deal. Use tools that help lift. Adjust tables. Add grip padding. It’s about making the job easier on the body. Less bending. Less strain. That means fewer injuries—and happier workers who stick around.
  • Clear Signage, Traffic Flow, and Visual Communication: Keep paths clear. Mark them well. Tape the floor. Add mirrors at corners. Put up signs people can see. Use vests that pop. Create hand signals everyone understands. Confusion causes crashes. Clear signals keep things smooth.
  • Well-Defined Emergency Protocols and Safety Drills: Emergencies happen. Fires. Spills. Malfunctions. Be ready. Put stop buttons where people can reach them fast. Make sure everyone knows the exits. Run drills. Post the rules on the wall. Practice. Repeat. One day, it could save someone’s life.

Final Thoughts

Material handling is more than just moving things from point A to point B—it’s about crafting a seamless flow of goods, information, and value throughout your operations. From simple storage racks to sophisticated automation, understanding the different types of material handling equipment empowers businesses to choose the right tools for the job.

Let’s quickly recap the key equipment types:

  • Storage Equipment helps you organize and maximize space.
  • Industrial Trucks boost mobility and handling flexibility.
  • Bulk Material Handling Systems are built for high-volume, granular movement.
  • Automated Systems offer precision, speed, and data integration.
  • Hybrid Solutions provide scalable efficiency without full automation investment.

Each category plays a crucial role in reducing labor, improving safety, and enhancing throughput—making them essential to nearly every industry from logistics to agriculture.

Whether you’re setting up a new warehouse or upgrading your existing operation, investing in the right material handling equipment can transform your efficiency, safety, and bottom line. Understanding your specific operational needs is the first step—choosing tools that scale with your business is the next.

To explore more expert insights and practical advice, be sure to visit our blog regularly. You can also learn more about the fundamentals of material handling and its benefits by visiting our detailed post on what is material handling and its benefits.

Have questions or need help choosing the right equipment? Contact us or visit our website today to speak with our experienced team. Let’s build smarter, safer, and more efficient operations—together.

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