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Material Handling Carts and Their Applications: A Comprehensive Guide

Material handling carts are integral to the operations of many industries. From warehouses to healthcare facilities, these carts assist with a variety of tasks, like material handling, maintenance, and organization. Whether you’re a metal fabricator looking to expand your services or a production manager who needs help deciding what cart to order, this post has you covered. We’ll discuss the various types of material handling carts, their applications, and how the right casters are a key part of their performance.

What Are Material Handling Carts?

Material handling carts are designed and produced for integration into a single company’s (typically in a warehouse, distribution center, or manufacturing plant) specific operational system. Often customized to meet specific requirements and standards for the company’s needs, they can vary widely in size, shape, and purpose. Carts are used in industrial, commercial, and medical settings, helping to increase efficiency and productivity. With a better understanding of what a material handling cart is, let’s look at some of the different types.

Utility Carts

What Are Utility Carts?

Also known as service carts, utility carts can vary widely, depending on the company's needs. One of the most versatile cart types, utility carts can be used for anything from tool organization to hotel housekeeping. Perfect for environments where quick access to tools, equipment, and supplies is necessary, they are lightweight and usually contain multiple shelves or compartments.

Utility Cart Applications

Automotive Workshops: Mechanics use these carts to keep tools and spare parts organized and within reach.

Hospitality Industry: Used by hotel housekeeping staff to transport cleaning supplies and linens effectively.

Maintenance Departments: Used by maintenance technicians to carry tools and supplies for repairs.

Healthcare Facilities: Used by healthcare providers to transport medical supplies and equipment.

Retail Stores: Used by back-end retail workers to assist with stocking and inventory management.

Catering Services: Used by waitstaff to transport food, beverages, and utensils during events and large gatherings.

Conveyor Carts

What Are Conveyor Carts?

Conveyor carts are designed to work seamlessly with conveyor systems, typically in assembly facilities. These carts, often equipped with conveyor belts or automated rollers, are designed to work seamlessly with conveyor systems, typically in automated rollers. These carts, often equipped with conveyor belts or automated rollers, are used to transfer goods to and from a stationary conveyor or delivery truck. They come in motorized and manual, as well as flexible and rigid varieties.

Conveyor Cart Applications

Manufacturing and Assembly Lines: Conveyor carts are used to move parts and components between different stages of the assembly process, such as transporting finished goods to packaging or storing areas.

Warehousing and Distribution Centers: Conveyor carts are used in the order fulfillment process at distribution centers, by transporting items from storage locations to shipping areas.

Automotive Industry: In automotive assembly and maintenance, conveyor carts are used to deliver parts and components to various production stations, helping to enhance efficiency. They are extremely helpful in moving heavy and large materials, like engines and chassis, reducing the need for manual handling.

Food and Beverage Industry: Conveyor carts are utilized on production lines to transport raw ingredients, packaging materials, and finished products. They can also be used to move products through different quality control checkpoints, ensuring consistency and compliance with company and government standards.

E-Commerce and Retail: In e-commerce fulfillment centers, conveyor carts play a crucial role in the efficient processing and shipping of online orders. They are also used to transport goods from receiving areas to storage shelves, helping with inventory management.

Platform Dollies

What Are Platform Dollies?

Also known as flatbed dollies, flatbed carts feature a flat surface, making them ideal for moving large loads that may not fit on standard carts. When equipped with the right casters, platform dollies balance ease of maneuverability with the ability to handle substantial weights.

Platform Dolly Applications

Construction Sites: Construction workers use platform carts to move construction materials and equipment, such as bricks, cement bags, and lumber across the construction site.

Hospitality and Event Management: Flatbed carts are used to transport equipment, staging materials, decorations, and supplies during event setup and teardown processes. They are also used for hotel housekeeping and maintenance to assist in moving cleaning supplies, linens, and maintenance equipment.

Agriculture and Horticulture: Flatbed dollies are used in nurseries and garden centers to facilitate the transport of pots, soil bags, and gardening tools. In agricultural settings, they are used to move harvested crops, plants, and farming equipment.

Warehousing and Logistics: Platform dollies are used to move heavy and bulky items, such as pallets, crates, and large boxes, within warehouses and distribution centers. They also assist in order picking and packaging, allowing warehouse clerks to transport multiple items simultaneously.

Manufacturing and Assembly: Flatbed carts are ideal for transporting raw materials, components, and finished products between different stages of the manufacturing process. They also help move tools, equipment, and parts to various workstations.

Retail and Commercial: In retail environments, platform dollies are used to transport inventory from storage areas to sales floors, facilitating restocking and merchandising. They are perfect for moving large items, such as furniture and appliances, in showrooms and warehouses.

Automated Guided Carts (AGCs)

What Are Automatic Guided Carts?

Automated guided carts, or AGCs are autonomous carts equipped with sensors and navigation systems that allow them to move independently along predefined paths. They can be designed for a variety of configurations, such as tow vehicles, unit load carriers, and pallet trucks, making them perfect for almost any operational requirement. AGCs can be integrated with other automated systems, such as conveyor belts, to help enhance efficiency and streamline workflow.

Automated Guided Vehicle Cart (AGC) Applications

Manufacturing and Assembly: AGCs transport components and materials to different stages of the production line, helping to keep up supplies stocked, while decreasing downtime. By programming these carts to deliver materials directly to specific workstations, manufacturers can limit delays and human error.

Warehousing and Distribution Centers: AGC carts automate the picking and packing process, moving items from storage locations to packing stations, without the need for manual labor. They also play a role in inventory management, assisting in the automated storage and retrieval of goods, which improves accuracy and optimizes space utilization.

Automotive Industry: AGCs are used to transport heavy and bulky automotive parts, such as engines and transmissions, along the production line. They ensure the timely delivery of components to various stages of the assembly process, supporting just-in-time manufacturing practices.

Pharmaceutical and Healthcare: AGC carts can transport pharmaceuticals, medical supplies, and laboratory samples in controlled environments, helping to ensure safety. They help move medical equipment, supplies, and linens, within hospitals, reducing manual handling and improving workflow.

Mother-Daughter Cart Systems

What Are Mother-Daughter Cart Systems?

Mother-daughter cart systems consist of a “mother” cart, which serves as a main transport vehicle, and one or more detachable “daughter” carts that can be loaded or unloaded independently. This modular approach allows for greater flexibility and efficiency, as daughter carts can be pre-loaded or unloaded while the mother cart continues its route. Mother-daughter cart systems come in a variety of cart options, including traditional tugger trains, hydraulic lift carts, and pass-throughs.

Mother-Daughter Cart System Applications

Manufacturing and Assembly: Mother-daughter cart systems efficiently deliver materials and manufacturing components to different individual workstations. The mother cart transports multiple daughter carts to different production areas, where they can be unloaded as needed.

Mother-daughter cart systems also support just-in-time manufacturing by ensuring that the right materials are delivered to the right place at the right time, reducing inventory and improving workflow efficiency.

Warehousing and Distribution Centers: In warehousing environments, the mother cart can transport multiple daughter carts filled with picked items to packing stations for processing. The systems streamline the movement of goods within the warehouse, improving inventory control and reducing time spent on material handling.

The Importance of Casters in Material Handling Carts

The effectiveness of your material handling carts heavily relies on their casters. Factors like wheel material, load capacity, and mounting type are choices that should be made at the beginning of the custom cart design process. Think about whether debris retention, static discharge, or excessive noise from your casters are issues you need to avoid and address them, early on. Are your carts going to be used for manual push/pull applications? Ergonomic casters can help you avoid injury in your facility by reducing impact on the neck and spine. Selecting the right casters can enhance the durability, maneuverability, and safety of any material handling cart in any application.

Carts are vital to meeting specific operational needs and improving efficiency in countless industries. By understanding the different types of material handling carts and their applications, you can empower yourself to choose the best solutions for your facility.

Need more information about caster selection, caster configuration, or caster measurements for OEM carts? Access our 3D CAD drawing configurator for access to downloadable CAD model drawings.

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