Selecting the right materials handling equipment (MHE) is crucial for improving efficiency, reducing operational costs, enhancing workplace safety, and maximizing warehouse productivity. With a wide variety of equipment available—including forklifts, pallet trucks, reach trucks, and automated systems—making the right choice depends on your specific operational requirements.

This guide will walk you through key considerations and decision-making steps to help you choose the best materials handling equipment for your business.

Step 1: Assess Your Operational Needs

Before purchasing any equipment, conduct a thorough analysis of your current and future operational requirements.

Key Questions to Ask:

• What types of materials are you handling? (e.g., pallets, cartons, rolls, drums)
• What are the average and maximum weights of the loads?
• How high do you need to lift materials? (stacking height, racking height)
• What is your daily volume of movements?
• Do you handle materials indoors, outdoors, or both?
• Are your aisles wide or narrow?
• What is your warehouse layout and racking system?
• Is automation or integration with WMS/ERP needed?

Step 2: Understand the Types of Materials Handling Equipment

1. Pallet Trucks (Manual or Electric)

Best for: Light-duty, short-distance movement of pallets.

Use Case: Loading/unloading trucks, moving goods across short distances in small warehouses.

Choose if: You need low-cost, simple transport over short distances and minimal lifting.

2. Counterbalance Forklifts (Electric, LPG, Diesel)

Best for: General-purpose lifting and transport in medium to large warehouses.

Use Case: Loading/unloading, stacking, moving heavy loads.

Choose if: You have wide aisles and need to lift heavy loads to moderate heights.

3. Reach Trucks

Best for: Narrow aisle operations with high stacking.

Use Case: Racking systems where space is limited; common in deep-lane or selective pallet racking.

Choose if: You want to maximize storage density in narrow aisles and need high stacking capability.

4. Narrow Aisle Trucks (e.g., Order Pickers, VNA – Very Narrow Aisle Trucks)

Best for: Extremely narrow aisles (as little as 1.6m), high storage density.

Use Case: Automated or semi-automated warehouses with high racking.

Choose if: Space is at a premium and you’re investing in a high-efficiency warehouse.

5. Stacker Trucks (Pedestrian or Rider)

Best for: Light to medium-duty stacking in small spaces.

Use Case: Retail backrooms, small warehouses, workshops.

Choose if: You need a compact solution for light loads and limited space.

6. Order Pickers

Best for: Picking individual items or small batches from racking.

Use Case: E-commerce fulfillment, parts distribution.

Choose if: Your operation involves frequent order picking at various heights.

7. Pedestrian Stackers

Best for: Low-lift stacking with operator walking behind.

Use Case: Tight spaces where riding trucks can’t operate; ideal for light-duty order assembly.

Choose if: You need a compact, low-cost solution for light loads in congested areas.

8. Tow Tractors (Tuggers)

Best for: Moving multiple carts or trailers in train formation.

Use Case: Assembly lines, large facilities with repetitive transport routes (e.g., manufacturing, airports).

Choose if: You move many small loads over long distances and want to reduce trips.

9. Container Handlers (Reach Stackers, Empty Container Handlers)

Best for: Loading, unloading, and stacking shipping containers.

Use Case: Ports, intermodal yards, distribution centers handling containers.

Choose if: You regularly handle 20ft or 40ft shipping containers and need outdoor-capable lifting.

10. Automated Guided Vehicles (AGVs) and AMRs

Best for: Hands-free, automated transport of materials.

Use Case: High-volume production, e-commerce fulfillment, repetitive workflows.

Choose if: You’re ready to invest in automation to improve accuracy, reduce labor costs, and scale operations.

11. Pallet In-Feed Systems

Best for: Automatically feeding pallets into production or packaging lines.

Use Case: Manufacturing, bottling, packaging plants.

Choose if: You need consistent, automated pallet supply without manual intervention.

12. Cranes & Hoists (Jib, Overhead, Gantry)

Best for: Lifting very heavy or bulky items (e.g., machinery, engines).

Use Case: Workshops, factories, maintenance bays.

Choose if: You handle oversized or extremely heavy loads that forklifts can’t manage.

13. Conveyor Systems (Roller, Belt, Gravity, Powered)

Best for: Continuous movement of goods between zones (e.g., packing, sorting, loading).

Use Case: Distribution centers, parcel hubs, production lines.

Choose if: You need high-throughput movement with minimal manual handling.

14. Docking Equipment (Dock Levellers, Yard Ramps, Vehicle Restraints)

Best for: Safe and efficient loading/unloading of trucks.

Use Case: Warehouses, distribution centers, retail backrooms.

Choose if: You load/unload multiple trucks daily and want to improve speed and safety at the dock.

Step 3: Consider Power Source Options

Step 4: Evaluate Warehouse Layout and Infrastructure

• Aisle Width: Measure your narrowest aisle. This determines whether reach trucks or VNA trucks are feasible.
• Racking Height: Ensure the lift height exceeds your highest load.
• Floor Condition: Smooth, level floors are essential for reach and VNA trucks.
• Doorways and Ramps: Check clearance for height, width, and incline.
• Power & Charging: Ensure access to charging stations or fuel sources.

Step 5: Calculate Total Cost of Ownership (TCO)

Don’t just look at the purchase price. Consider:

• Initial purchase or lease cost
• Energy/fuel costs
• Maintenance and servicing
• Operator training
• Downtime impact
• Resale value

Step 6: Prioritize Safety and Operator Comfort

• Choose equipment with safety features: seat belts, warning lights, stability systems.
• Ensure ergonomic design to reduce operator fatigue.
• Provide proper training and certification.
• Consider telematics for monitoring usage and safety.

Step 7: Plan for Scalability and Future Needs

• Will your volume grow in the next 3–5 years?
• Are you planning to automate or integrate with warehouse systems?
• Can your equipment scale with new workflows or expansions?

Step 8: Consult with Suppliers and Test Equipment

• Work with reputable suppliers who offer support and training.
• Request on-site demonstrations or trial periods.
• Ask about service contracts and spare parts availability.

Final Checklist Before Purchase

• Defined load weight and dimensions
• Measured aisle widths and ceiling heights
• Confirmed indoor/outdoor usage
• Selected appropriate power source
• Evaluated operator skill level and training needs
• Calculated TCO (not just upfront cost)
• Verified safety and compliance standards
• Considered service and maintenance support
• Assessed need for automation or integration

Conclusion

Choosing the right materials handling equipment isn’t a one-size-fits-all decision. By analyzing your needs, layout, and future goals, you can select equipment that boosts productivity, ensures safety, and delivers long-term value.

When in doubt, consult a materials handling specialist to conduct a site assessment and recommend the best solutions for your operation.

Invest wisely—your equipment choices today will shape your warehouse efficiency for years to come.