Material handling is one of those terms that sounds technical—until you realize it’s simply how things move and get stored in your facility. Every time a pallet is unloaded, a box gets staged, a part is carried to a workbench, or an order is packed and sent out, you’re doing material handling.
The Material Handling Industry (MHI) describes material handling as the movement, protection, storage, and control of materials and products throughout manufacturing and distribution. Source: MHI
If you’re looking to upgrade your setup, you can browse everything in one place here: Shop all material handling.
Why material handling affects profit (even if you don’t notice it day to day)
Most operations don’t “feel” the cost of inefficient handling because it shows up in small ways:
- a picker walking 30 extra steps per order,
- a box being moved twice because staging isn’t clear,
- a team member lifting awkwardly because storage is too low or too high,
- a pallet jack stuck because aisles are cluttered.
Those small frictions repeat hundreds of times. Over weeks and months, they become real labor cost, missed ship cutoffs, returns, and injury risk.
OSHA emphasizes safe practices for handling and storing materials to prevent injuries and costly incidents. Source: OSHA (PDF)
The everyday places material handling breaks down
Receiving turns into a pile-up
Inbound arrives, but putaway doesn’t keep up—so staging becomes permanent storage. That usually creates downstream problems: blocked aisles, longer travel paths, and more damage.
Storage feels random
When locations aren’t clear, people rely on memory. That’s when you get “search time,” wrong picks, and a constant feeling of mess. This is where the basics often deliver quick wins:
- Shelving & racking for consistent locations and better space use
- Storage containers to standardize bins, protect parts, and make picking faster
OSHA requires stored materials to be stacked and secured to prevent sliding/collapse hazards. Source: OSHA 1910.176
People are carrying things they shouldn’t carry
In workshops especially, people often “just carry it” because it’s quicker in the moment. Over time, it’s one of the fastest ways to burn labor and increase injury risk. Two categories that usually pay for themselves:
- Hand trucks for boxes, equipment, and quick moves
- Carts & trucks for kitting, WIP movement, and packing workflows
Pallets are moved inefficiently
If your team is moving pallets with improvised methods (or waiting on a forklift for short moves), you’ll see delays at docks and staging. For short-distance pallet movement, pallet trucks are often the workhorse.
If you use powered industrial trucks, OSHA’s standard 29 CFR 1910.178 outlines safety requirements for their use and training. Source: OSHA 1910.178
A quick way to improve handling without redesigning your whole facility
You don’t need a full-blown system overhaul to get meaningful improvement. In many warehouses and workshops, the best gains come from reducing repeat work:
- Keep fast-moving items closer to the pack/ship or work area
- Use containers to standardize small parts and reduce “search time”
- Give movement a tool (carts, hand trucks) instead of human carrying
- Make staging zones obvious so pallets don’t drift into aisles
- Store at safer reach heights (most-used items between knee and shoulder)
NIOSH provides ergonomic guidance for manual material handling and tools for evaluating lifting risk (including the Revised NIOSH Lifting Equation). Source: NIOSH/CDC (PDF)
What to buy first (if you’re starting from scratch)
If you’re building a practical baseline for daily operations, these are common “first upgrades”:
- Pallet trucks for dock and staging moves
- Carts & trucks for picking routes, packing support, and WIP movement
- Hand trucks for fast box and equipment transport
- Shelving & racking for clearer storage and better space use
- Storage containers to reduce errors and speed up picking
Want to describe your layout and get a recommendation list that matches your workflow (warehouse vs workshop, pallet vs carton, order volume, aisle width, etc.)? Contact us.
Or browse by category here: Shop all material handling.
FAQ
What is material handling?
Material handling refers to how materials and products are moved, stored, protected, and controlled in a warehouse, workshop, or production environment. Source: MHI
What is considered material handling equipment?
Common equipment includes pallet trucks, carts and trucks, hand trucks, shelving and racking, and storage containers—anything that helps move and organize items more safely and efficiently.
How can I reduce manual lifting risk?
Use carts/hand trucks instead of carrying, store frequently used items at safer heights, reduce twisting, and follow ergonomic guidance such as NIOSH manual material handling recommendations. Source: NIOSH/CDC
Where can I shop material handling supplies?
You can browse by category here: Shop all material handling.