Walk into any busy warehouse, and you’ll see the same pattern. Pallets are coming off the trucks, stock is going toward the racking, and orders are being picked and packed for the next shipment. All of that’s not done by hand anymore. That’s what it is, that somebody picks the right equipment for every part of that flow.
This guide will take you through the main types of material handling equipment in warehouses, what each one does best, and how to match equipment to your actual operation, as opposed to buying what’s popular.
What Is Material Handling Equipment?
Material handling equipment, or MHE for short, is the general term for the machines and tools used to move, lift, store, and protect goods within a facility. In a warehouse specifically, that can be anything from a hand truck to move a single box to a fully automated 24/7 storage and retrieval system.
Most equipment in this space can be grouped into a few functional categories: • Transport equipment, which moves goods from one point to another • Storage equipment, which organises and protects inventory • Lifting or positioning equipment, which raises, lowers, or angles a load at a fixed location. Typically, warehouses use a combination of all three, the right combination depending a lot on the size of the facility, the type of goods being handled, and the frequency of stock turnover.
Why Equipment Choice Matters in a Warehouse
Choosing the wrong gear is quickly apparent in a warehouse. Increases order fulfilment times. Workers are bending their backs, lifting things a machine should be doing. The aisles get blocked because the forklift can’t make the turns it needs to make.
Here’s why this matters beyond everyday convenience. Manual lifting and repetitive carrying are two of the largest contributors to musculoskeletal injuries in warehouse work, and those injuries represent a large part of lost workdays across the industry. Powered equipment removes a lot of that physical strain, but it needs to be the right size and type for the job.
And there is a compliance angle too. Powered industrial trucks are regulated by the Occupational Safety and Health Administration (OSHA) under 29 CFR 1910.178. Forklifts alone are linked with approximately 70-85 workplace fatalities and tens of thousands of serious injuries each year in the United States. It’s not just paperwork to get the equipment selection and operator training right. It’s the difference between a warehouse working safely and a warehouse waiting for something to go wrong.”
Types of Material Handling Equipment in Warehouse Operations
Let’s review the types of equipment you will find in most warehouses, beginning with the most common and working our way to the more specialised.
1. Forklifts
Forklifts are the backbone of warehouse materials handling. They lift, haul, and stack palletised loads and are used for everything from unloading delivery trucks to placing pallets on high racking.
OSHA divides forklifts into seven types, ranging from electric-motor rider trucks used inside to rough-terrain forklifts for rough outdoor terrain. Each class requires its own training and certification, and just because an operator is certified on one type doesn’t mean they’re automatically good to run another type. For example, a counterbalance forklift and a reach truck need different aisle widths and different handling techniques, although both are classified as forklifts.
2. Pallet Jacks
A pallet jack (or pallet truck) has two forks and a hydraulic pump which allows it to raise and move one pallet at a time. Manual pallet jacks are good for short, infrequent moves. Electric pallet jacks are sometimes called walkies or rider trucks. They are powered by a battery-powered motor and can do longer runs or heavier loads without tiring the operator. Neither type lifts to the height of racking, where forklifts and stackers enter the picture.
3. Stackers
Stackers are somewhere between pallet jacks and full forklifts. A hand stacker is manual. It is good for lighter loads at moderate heights. An electric stacker handles heavier loads and taller lifts with less physical effort. Stackers fill this gap for warehouses that move a lot of palletised goods each day but don’t need the full lift range of a forklift.
4. Order Pickers
Order pickers raise the operator to the height of the shelf so they can select individual items without having to climb a ladder or continually move equipment. This is most critical in facilities that handle large volumes of piece-level order fulfilment, where speed and accuracy on each pick directly impacts how quickly orders get out the door.
5. Conveyors
Conveyors move goods along a fixed path; no person carries each item by hand. They most commonly exist in receiving, sorting, and shipping areas where the same type of material is flowing back and forth between two points. A conveyor system is not going to replace a forklift in moving pallets around a warehouse, but for a continuous, high-volume flow along a set route, nothing delivers the consistency of a conveyor system.
6. Pallet Racking and Shelving
Storage equipment such as pallet racking and shelving stores inventory vertically and is a much better use of available floor space than just stacking goods on the ground. Good racking design reduces product damage and makes it easier to know what’s stored where. Most warehouses connect racking systems directly to the forklifts and order pickers that access them, so the two should be planned together rather than as separate decisions.
7. Hand Trucks and Platform Trucks
Hand trucks have a metal frame and toe plate and are used to move smaller, lighter items around a facility without the use of hydraulics or a motor. Platform trucks take that idea a step further, with a wider platform and four wheels instead of two, which means they can carry bulkier loads over short distances. Both are simple, cheap tools for moves that don’t need a forklift or pallet jack.
8. Sideloaders
A sideloader is a type of narrow-aisle forklift. The operator’s cab is mounted alongside the vehicle rather than the front, reducing the turning space needed to put loads onto racking. In warehouses with narrow aisles or facilities that move long or oversized loads such as lumber or pipe, where a standard forklift would not fit, sideloader forklifts are commonly used.
9. Automated Guided Vehicles and Robots
Automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) transport loads from one place to another in a facility without a human operator. Towing AGVs tow multiple carts behind them. Unit load handlers move single pallets or objects from point to point. You see these more in larger distribution centres where the volume justifies the investment. They’re also becoming more common as automation costs come down.
10. Automated Storage and Retrieval Systems (AS/RS)
An AS/RS is a computer-controlled system for automatically storing and retrieving loads in storage locations, typically in high-density environments where manual access is slow or impractical. They are good for facilities with consistent, high-volume storage needs and less so for smaller operations with constantly changing inventory.
11. Trolleys, Drum Handlers, and Small Lifting Equipment
Not every warehouse move is a full pallet. For the shorter, more localised tasks, such as moving a drum a few feet, positioning a component for assembly or lifting a spool onto a shelf, drum trolleys, hand-operated lifting points and small electric hoists are used. These lesser tools are often overlooked in planning equipment, but they fill real gaps between manual lifting and complete mechanisation of handling.
How to Choose the Right Equipment for Your Warehouse
There is no “best” piece of equipment. The best choice will depend on your particular operation. Some questions to work through before buying:
- What is the average load weight and configuration, and is the rated capacity of the equipment a comfortable margin?
- What is the width of the aisles, and does the equipment have to make tight turns or manoeuvre through small spaces?
- Occasional use or continuous shifts? How often will the equipment be in operation?
- Are operators certified and trained for this class of equipment?
- Are your storage layout, racking height, and floor surface compatible with the equipment’s design?
Getting these details right before you buy will save you money later on. Equipment that is too small for the job wears out quickly and is a safety hazard. Oversized equipment for your true volume ties up capital that could be spent on something more useful.
Safety and Training Requirements
OSHA’s standard for powered industrial trucks demands formal instruction, hands-on practical training, and a documented performance evaluation before anyone is permitted to operate a forklift or similar equipment. Operators should be re-evaluated at least every three years or sooner if unsafe operation is observed on the floor. Also, equipment must be inspected before each shift, and any truck with a safety defect must be removed from service immediately.
These are not simply legal tick boxes. A warehouse that takes training and inspection seriously has fewer accidents, less equipment downtime and fewer disputes when something does go wrong.
A Word on Sourcing Warehouse Equipment
When buying lifting and handling equipment for a warehouse, the sticker price isn’t everything. Build quality, load ratings, and access to spare parts and support after the sale all matter when equipment is actually in daily use. Since 1983, M.A. Zavery has supplied hoists, winches, wire rope, and rigging equipment throughout India, and the company’s product range includes manual and electric hoists, stackers, drum trolleys, and lifting points for the smaller-scale lifting and positioning tasks encountered throughout warehouse operations. No matter what kind of equipment your facility needs, partnering with a supplier that has solid experience in that particular category usually pays off over the life of the equipment.
Final Thoughts
Rarely is a warehouse powered by a single piece of equipment. Forklifts, pallet jacks, stackers, conveyors, racking, and smaller lifting tools all handle different parts of the flow, and most facilities find they use several of these in concert. Match equipment to the actual size of your loads, aisle widths, and volume, and be sure operators are properly trained on what you bring onto the floor. That upfront planning pays off in fewer injuries, less downtime, and a warehouse that actually moves at the pace your business needs.
Frequently Asked Questions
What is the most commonly used equipment in a warehouse?
The most common equipment used in warehouses is pallet jacks and forklifts, because they are responsible for most of the movement of pallets, from unloading trucks to placing items on racking. Receiving and picking areas also widely use conveyors and hand trucks.
What’s the difference between a pallet jack and a forklift?
A pallet jack will lift a pallet only a few inches off the floor for short moves and cannot reach racking height. A forklift stacks pallets on racking and lifts loads much higher, and it requires formal operator certification under OSHA rules.
Do all warehouse workers need training to operate material handling equipment?
Powered industrial trucks such as forklifts, reach trucks, and order pickers must be operated by trained and certified operators, according to OSHA regulations. Training must include formal instruction, practical hands-on experience, and a documented evaluation before anyone is permitted to operate the equipment unsupervised.
When does a warehouse need an automated storage and retrieval system instead of standard racking?
AS/RS systems are appropriate for facilities with a large, consistent storage volume that would be too slow to access manually or where floor space is tight. Standard racking with forklift or order picker access provides the best value for smaller operations with frequently changing inventory.
What should I consider when buying hoists or lifting equipment for a warehouse?
Make sure the equipment’s rated load capacity matches your actual lifting needs, fits your ceiling height and workspace, and you’re buying from a supplier with experience in that particular equipment category. Old-timers like M.A.Zavery have decades of experience in hoists and rigging equipment and tend to give better advice on matching equipment to the task.