BATANGAS STATE UNIVERSITY

College of Engineering, Architecture and Fine Arts

Gov. Pablo Borbon Campus II,
Alangilan, Batangas City, Philippines 4200
www.batstate-u.edu.ph Telefax: (043) 300-4044 locs. 106-108

CHEMICAL AND FOOD ENGINEERING DEPARTMENT

ChE 423
EQUIPMENT DESIGN

MATERIAL HANDLING

Arellano, Oliver E.
Catacutan, Ronalyn
Maibo, Mariel I.
Panganiban, Glycel
ChE - 4201
 Engr. Angelica D. de Sagun

Instructor 1
Materials Handling
I. Introduction
Material handling systems consist of discrete or continuous resources to
move entities from one location to another. They are more common
manufacturing systems compared to service systems. Apple (1977) notes that
material handling can account for up to 80 percent of production activity.
Although material movement does not add value in the manufacturing process,
half of the companys operation costs are material handling costs (Meyers,
1993).
Material handling is the movement, protection, storage and control of
materials and products throughout manufacturing, warehousing, distribution,
consumption and disposal. As a process, material handling incorporates a wide
range of manual, semi-automate and automated equipment systems that support
logistics and make the supply chain work,
II. Storage and Handling Equipment
Storage equipment is usually limited to non-automated examples, which are
grouped in with engineered systems. Storage equipment is used to hold or
buffer materials during downtimes, or times when they are not being
transported. These periods could refer to temporary pauses during long-term
transportation or long-term storage designed to allow the buildup of stock.
The majority of storage equipment refers to pallets, shelves or racks onto
which materials may be stacked in an orderly manner to await transportation
or consumption. Many companies have investigated increased efficiency
possibilities in storage equipment by designing proprietary packaging that
allows materials or products of a certain type to conserve space while in
inventory
A. The equipment
a. Racks
i. Pallet racks
1. Single deep rack - The simplest of all racking
systems, it permits only one-unit-deep pallet loads to
be stored side-by-side. This makes all pallets
accessible from the aisle, which is why it is also called
selective rack, or single deep selective rack. For
greater storage density, double deep rack
accommodates two pallet loads stacked back-to-back.
2. Drive in rack Ideal for storing repetitive products
while maximizing cubic storage space, this structure
allows a vehicle to enter from one side only to pick up
or deliver pallets that rest on continuous rails. A drive
in rack structure is utilized when a last-in, first-out
(LIFO) inventory system is required. Similarly-
constructed, drive through rack permits a vehicle to
drive through the structure at any storage location
along the aisle.
3. Carton flow rack or flow-through rack Ideal for
small-quantity case picking, this system utilizes metal
 shelves equipped with rollers or wheels that allow
product and materials to flow from the back of the
rack to the front. Similar in concept but on a larger
scale is pallet flow rack which uses conveyor wheel
shelf sections that enable back-loaded pallets to flow
by gravity to the front or pick face. Both carton flow
and pallet flow are implemented when a first-in/first-
out (FIFO) inventory system is required. Also utilizing
wheels in the rack structure, push back rack allows
palletized goods and materials to be stored by being
pushed up a gently graded ramp. Push back,
however, differs from carton flow and pallet flow in
that it offers a LIFO inventory system.
4. Cantilever rack - A center column-based rack with
arms projecting from the columns for front-loading of
large objects without obstruction from rack support
uprights.
5. Reel rack Storage system specifically used to store
reels of cable or cord by cradling them in the rack.
6. Mobile rack or mobile sliding rack- Typically a single
deep selective rack with wheels at the base for
movement of the entire structure along tracks
embedded in the facilitys floor.
7. Portable rack Self-contained rack units made up of
bases, decks and posts available for temporary
expanded storage as needed.
ii. Drive-through
iii. Drive-in racks
iv. Push-back racks
v. Sliding racks
b. Stacking frames
c. Shelves, bins
i. Shelving: Convenient and cost-effective, this type of storage
system is comprised of more than one shelf for storage of
non-palletized loads, typically hand-loaded, light loads. Open
type shelving is comprised of upright posts, formed steel
sheet panels that attach horizontally to the posts to support
the loads, and end and back braces. Sheet steel back and
side panels may be substituted for bracing to form closed
shelving units.
ii. Commercial shelving is made from lighter gauge materials
and carries a 350-pound load limit per shelf (the loading is
typically understood to be applied uniformly across the entire
surface of the shelf). Industrial shelving is made from heavier
gauge materials and accommodates weights of 750 pounds
per shelf or more. For internal organization, formed steel
partitions, or shelf dividers subdivide the shelf openings to
form smaller compartments.
iii. Systems can be in single, double or multiple rows, with
single or double face shelving. All are accessed by
personnel from a shelving service aisle for stock picking or
placing.
iv.
v. Other types of shelving include:
 vi. Two level - Two shelf levels are tiered one on top of each
other with each tier serviced from a separate level. Similarly,
multi level shelving has three or more shelf levels tiered one
on top of the other with each tier serviced from a separate
level. Typically each level is 8 to 10 feet high. Reaching
heights in excess of 30 feet, the tallest version of these
stacked shelves is high rise shelving, which is serviced by
rolling ladders.
vii. Gondola or library shelving This is a floor mounted system
utilizing cantilevered, easily repositioned shelves extending
from one or both sides of a rigid vertical back.
viii. Ledge type shelving - A unit that holds two different depths of
shelves, with larger shelves on the bottom, and smaller,
stepped-back shelves on the top.
ix. Mobile shelving - A self-contained system mounted on a floor
rolling system or suspended from overhead tracks that
allows each unit within to move apart or nest against each
other for enhanced space savings and accessibility.
x. Record shelving or archive shelving - A system to store files
and records that is usually closed on three sides and may
have retractable or swing up and down opening covers for
security, protection and cleanliness
d. Drawers - For applications where volume of inventory turnover is
low and where smaller items are being stored, drawers can be
used. Variations include modular drawers that can be partitioned to
organize contents. The drawers can be integrated into a wheeled or
stationary cabinet, in shelving, or as a component of modular office
furniture used in the workspaces of a facility.
e. Mezzanine - A structure built within an existing facility that is
designed to maximize clear space under and above it. Accessed by
steps or integrated personnel or load lifts, a mezzanines
construction depends on the amount of load, the clear distance it is
required to span and types of activities it will support.
i. Free standing - A standalone structure that incorporates wide
column spacing and high load carrying capacity (typically
stated in pounds per square foot capacity).
ii. Integrated Constructed as an integral part of a buildings
structure, this type of mezzanine can incorporate wider span
distances between support columns while still maintaining a
high load carrying capacity (typically stated in pounds per
square foot).
iii. Modular Standardized and pre-fabricated, these structures
come in pre-packaged, off-the-shelf sizes for quick delivery
and installation, but have lighter load carrying capacities
(also typically stated in pounds per square foot).
Racks, such as pallet racks, drive-through or
drive-in racks, push-back racks, and sliding
racks

Source: http://www.ontarioindustrial.com/
Stacking frames

Source: https://www.worksafe.qld.gov.au
Shelves, bins and drawers

Source:
http://www.nationwideindustrialsupply.com

Mezzanines

Source: http://www.aw-systems.com

III. Engineered Systems

a. Automated guided vehicles
- AGVs do not require an operator
- Good for high labor cost, hazardous, or environmentally sensitive
conditions (e.g., clean-room)
- Also termed "automated" guided vehicle
- AGVs good for low-to-medium volume medium-to-long distance random
material flow operations (e.g., transport between work cells in a flexible
manufacturing system (FMS) environment)

Two means of guidance can be used for AGV systems:

i. Fixed path: Physical guidepath (e.g., wire, tape, paint) on the floor used
for guidance
ii. Free-ranging: No physical guidepath, thus easier to change vehicle path
(in software), but absolute position estimates (from, e.g., lasers) are
needed to correct dead-reckoning error

b. Conveyors
Flat belt conveyor - Flat belt conveyor is
that in which the belt runs flat on the carrying
side over straight roller type idler or a set of
idlers. Flat belt conveyors are suitable for
lower capacity, low speed requirement and
for handling unit goods or bulk material of
small lump size and higher angle of repose.
Declination is undesirable. Source: http://beltconveyorsystems.in/products/
Belt Conveyor is typically used in package
handling, raw material handling, and small
part handling. It is effectively used for
elevation change or incline/decline
applications. A more common application of
belt conveyor you might not notice is in the
check-out line at your local grocery store.
Source:
http://www.haroldsequipment.com/equipment/belt-
conveyors
Minimum Pressure Conveyor is used in
short sections of accumulation, general
transport of product, and is ideal for medium
to light loads such as package handling
applications.

Source: http://www.automatedconveyors.com/
Drag Chain is typically used for handling
extremely heavy loads, special pallet
configurations, and extremely low- to high-
temperature areas.

Source: http://sites.dksh.com/htm/620/en/Drag-
Chain-Interflex-SLE-Steel-line.htm
Roller Roller pallet conveyor is typically
used for handling extremely heavy loads and
is ideal for accumulation zones in pack out
areas.

Source: http://www.arrcoolingtowers.com/roller-
conveyors.html

Live Roller Conveyor is typically used in

general transport when product accumulation
is not required. It is also used in package
handling applications and is ideal for light- to
medium-product loads.

http://www.lewcoinc.com/conveyors/conveyors
Diverter Source: http://www4.ncsu.edu/
Stationary or movable arms that
deflect, push, or pull a product to
desired destination
Since they do not come in contact
with the conveyor, they can be used
with almost any flat surface conveyor
Usually hydraulically or pneumatically
operated, but also can be motor
driven
Simple and low cost
Pop-Up Device Source:
One or more rows of powered rollers
or wheels or chains that pop up above
surface of conveyor to lift product and
guide it off conveyor at an angle;
wheels are lowered when products
not required to be diverted
Only capable of sorting flat-bottomed http://www4.ncsu.edu/
items
Pop-up rollers are generally faster
than pop-up wheels
Sliding Shoe Sorter Source:
Sliding shoe sorter (a.k.a. moving slat
sorter) uses series of diverter slats
that slide across the horizontal
surface to engage product and guide
http://www4.ncsu.edu/
it off conveyor
Slats move from side to side as
product flows in order to divert the
product to either side
Gentle and gradual handling of products

c. Automated Storage and Retrieval Equipment

There are several types of automated storage and retrieval
systems. Their common feature is the ability to quickly and directly
access each designated storage location. There are also different
levels of automation for these systems, depending on the type of
equipment used.
Storage and retrieval systems primarily are used to:
Store raw materials or bulk containers of goods for later use in
manufacturing or distribution operations
Temporarily store or buffer items between various manufacturing
processes
Store and stage items for picking and kitting in distribution or assembly
operations
Store and sequence finished goods in manufacturing facilities prior to
shipping

i. Unit-load AS/RS or Fixed-aisle (F/A) storage and retrieval

systems Machines that store large loads (usually 1,000+
pounds), typically on pallets. These systems include one or more
long and narrow aisles of storage rack structure, reaching 100 feet
or more tall. Most systems are less than 40 feet tall. Software
directs the automatic placement and retrieval of loads by a
 telescoping device that deposits loads into, or retrieves them out of,
specific storage positions.
ii. Mini-load AS/RS Operating the same way as a unit-load AS/RS,
a mini-load AS/RS handle lighter loads, usually weighing less than
1,000 pounds. Instead of storing pallets, the machines typically
store trays, totes or cartons.
iii. Micro-load AS/RS Dealing with loads even lighter than a mini-
load AS/RS, a micro-load AS/RS usually handles loads weighing
less than 100 pounds in very small containers, totes or trays.
iv. Vertical lift modules (VLMs) VLMs consist of a column of trays
in the front and back of the module with an automatic
inserter/extractor in the center that stores and retrieves the required
trays. Trays can be stored in fixed positions to improve throughput,
dynamically to optimize storage capacity, or as a combination of
both. Integrated controls, software and pick-to-light systems help
increase accuracy and storage densities.
v. Horizontal carousels Ideal for storing small parts and pieces,
horizontal carousels are comprised of a series of bins that rotate
horizontally around a track, similar to a merry-go-round. This
system usually employs two to five horizontal carousels in an
integrated workstation called a pod. When an operator inputs
inventory information into the carousels control software, the
carousels rotate into appropriate picking positions. A pick-to-light
device between each carousel illuminates to indicate from which
carousel, shelf and item to pick the required quantity. The operator
picks out of each carousel until the batch is complete. Inventory can
be inserted manually or robotically using an automated
inserter/extractor.
vi. Vertical carousels Rotating vertically, like a Ferris wheel, vertical
carousels house a series of shelves or carriers to provide high-
density storage that is ideal for fast-moving, small items. Often
used for tooling, components, documents or raw materials storage,
vertical carousels are enclosed on all sides to secure high-value
items, such as jewelry and electronics. When an operator inputs
inventory information into the carousels control software, the
machine rotates via the shortest path to position the items specific
storage shelf at the picking window. Integrated pick-to-light
technologies aid in determining the correct item and quantities to
pick.
Unit Load Automated Storage & Retrieval
Systems (AS/RS)
These systems are designed to handle
common size unit loads such as totes or
pallets of goods. The goods are usually
stored on static racking (or on pitched gravity
conveyors in flow through systems). The
items are stored and retrieved via automated
cranes that move through aisles between the
racks.
Source: http://www.isddd.com
 Vertical Lift Module (VLM) Storage
& Retrieval Systems
These systems are primarily intended to store
product for quick access in picking and kitting
operations. Goods are placed on trays that
are stored and retrieved by a shuttle
mechanism within the unit. Some
advantages of this unit are:
Fast, direct, random access to all
stored items
Secure storage of items within the
unit's enclosure
Dense storage of items in a small
footprint
Better utilization of vertical building
space
Automatic presentation of the next
item to pick
Reduction of worker travel distance to
retrieve or store items
Multiple access points on the same or
multiple building floors are possible
Available with refrigerated enclosures

Carousel-type Storage & Retrieval

Systems
Carousels come in vertical and horizontal
models and have the same uses as Vertical
Lift Module-type storage and retrieval units.
Goods are stored on shelves in vertical
carousels and in bins or shelves on horizontal
carousels. The shelves or bins are linked to
each other by a chain. Like the name
implies, the units rotate in a carousel-like
manner to the appropriate item storage
location. Vertical carousels have the same
advantages as VLM-type storage systems
except for the direct, random access and
multiple access points.

IV. Ten Principles of Material Handling

If material handling is designed properly, it provides an important support
to the production process. The Ten Principles of Material Handling was
developed by the MHIA.
A. Planning
A plan is a prescribed course of action that is defined in advance of
implantation.
Material handling plan defines:
1. What materials,
 2. When and where to move them,
3. How and who the method define
Five key aspects must be considered in developing a plan:
1. The plan should be developed in consultation between the planner(S)
and all who will use and benefit from the equipment to be employed.
2. Success in planning large-scale material projects generally requires a
team approach involving suppliers, consultants when appropriate, and
end-user specialists from management, engineering, computer and
information systems, finance, and operations.
3. The material handling plan should reflect the strategic objectives of the
organization, as well as the more immediate needs.
4. The plan should document existing methods and problems, physical
and economic constraints, and future requirements and goals.
5. The plan should promote concurrent engineering of product, process
design, process layout, and material handling methods, as opposed to
independent and sequential design practices.
B. Standardization
Material handling methods, equipment, controls, and software should be
standardized within the limits of achieving overall performance objectives
and without sacrificing needed flexibility, modularity, and throughput.
Standardization means less variety and customization in the methods and
equipment employed.
Three Key Aspects of Achieving Standardization:
1. The planner should select methods and equipment that can perform a
variety of tasks under a variety of operating conditions and in
anticipation of changing future requirements.
2. Standardization applies to sizes of containers and other load-forming
components, as well as operating procedures and equipment.
3. Standardization, flexibility, and modularity must be incompatible.
C. Work
The measure of work is material handling flow (volume, weight, or
count per unit of time) multiplied by the distance moved. Material
handling work should be minimized without sacrificing productivity
or the level of service required of the operation.
Key points in optimizing the work.
1. Simplifying processes by reducing, combining, shortening, or
eliminating unnecessary moves will reduce work.
2. Consider each pick-up and setdown that is placing material in
and out of storage as distinct moves and components of the
distance moved.
3. Process methods, operation sequences and process/equipment
layouts should be prepared the support the work minimization
objective.
4. Where possible, gravity should be used to move materials or to
assist in their movement while respecting consideration of
safety and the potential product damage.
5. The shortest distance between two points is a straight line.
D. Ergonomics
 Ergonomics is the science that seeks to adapt work or working
conditions to suit the abilities of the worker.
Two key points in the ergonomic principles:
1. Equipment should be selected that eliminates repetitive
and strenuous manual labor and that effectively interacts
with human operators and users. The ergonomic principle
embraces both physical and mental tasks.
2. The material handling workplace and the equipment
employed to assist in that work must be designed so they
are safe for people.
E. Unit Load
Unit load is one that can be stored or moved as a single entity at
one time. e.g. pallet, container or tote, regardless of the number of
individual items that make up the load.

Six key aspects deserve attention (when unit load is used in

material flow):
1. Less effort and work are required to collect and move many
individual items as a single load than to move many items one
at a time.
2. Load size and composition may change as material and
products move through stages of manufacturing and the
resulting distribution channels.
3. Large unit loads are common both pre- and post-manufacturing
in the form of raw materials and finished goods.
4. During manufacturing, smaller unit loads, including as a few as
one item, yield less in-process inventor and shorter item
throughput times.
5. Smaller unit loads are consistent with manufacturing strategies
that embrace operating objectives such as flexibility continuous
flow, and just-in-time delivery.
6. Unit loads composed of a mix of different items are consistent
with just-in-time and/or customized supply strategies as long as
item selectivity is not compromised.
F. Space Utilization
Space in material handling is three-dimensional and therefore I
counted as cubic space.
Three step process in space utilization:
1. Eliminate cluttered and unorganized spaces and blocked aisles
in work areas.
2. In storage areas, balance the objective of maximizing storage
density against accessibility and selectivity
3. Consider the use of overhead space wen transporting loads
within a facility. COI is a storage policy in which each item I s
allocated warehouse space based n the ration of its storage
space requirements (its cube) to the number of storage.
Retrieval transactions for that item.
G. System
 System is a collection of interacting or interdependent entities that
form a unified whole.
Five Aspect of the System Principle:
1. Systems integration should encompass the entire supply chain,
including revers logistics. It should include suppliers,
manufacturers, distributors, and customers.
2. Inventory levels should be minimized at all stages of production
and distribution while respecting considerations of process
variability and customer service.
3. Information flow and physical material flow should be integrated
and treated as concurrent activities.
4. Methods should be provided for easily identifying materials and
products, for determining their location.
5. Customer requirements ad expectations regarding quantity,
quality and on-time delivery should be met without exception.

H. Automation
Automation is concerned with the application of electro-mechanical
devices, electronics, and computer-based systems to operate and
control production and service activities.
Four Key Points in Automation
1. Preexisting processes and methods should be simplified and/or
re-engineered before any efforts at installing mechanized or
automated systems.
2. Computerized material handling systems should be considered
where appropriate for effective integration of material flow and
information management.
3. All items expected to be handled automatically must have
features that accommodate mechanized and automated
handling.
 4. All interface issues should be treated as critical to successful
automation, including equipment to equipment, equipment to
load, equipment to operator, and control communications.
F. Environment
Environment consciousness stems from a desire not to waste
natural resources and to predict and eliminate the possible negative effects of
our daily actions on the environment.
Key points for the environment
1. Containers, pallet and other products used to form and protect
unit loads should be designed for reusability when possible
and/or biodegrability as appropriate.
2. System design should accommodate the handling of spent
dunnage, empty containers, and other byproducts of material
handling.
3. Materials specified as hazardous have special needs with
regard to spill protection, combustibility and other risks.
I. Life Cycle
Life-cycle cost include all cash flows that will occur between the
time the first dollar is spent to plan or procure a new piece of
equipment, or to put in place a new method, until that method
and/or equipment is totally replaced.
Four Key Aspects:
1. Life cycle cost include capital investment, installation, setup and
equipment programming, training, system testing and
acceptance, operating, maintenance and repair, reuse value,
and ultimate disposal.
2. A plan for preventive and predictive maintenance should be
prepared for the equipment, and the estimated cost of
maintenance and spare parts should be included in the
economic analysis.
3. A long-range plan for replacement of the equipment when it
becomes obsolete should be prepared.
4. Although measurable cost is a primary factor, it is certainly not
the only factor in selecting among alternatives.
V. Types of Material Handling Equipment
A. Conveyors
These are fixed path MHDs. It should only be considered only when
the volume of parts or material to be transported is large and when
the transported material is relatively uniform in size and shape.
Types of conveyor
1. Accumulation conveyor
2. Belt conveyor
3. Bucket conveyor
4. Can conveyor
5. Chain conveyor
6. Chute conveyor
7. Gravity conveyor
8. Power and free conveyor
9. Pneumatic or vacuum conveyor
10. Roller conveyor
11. Screw conveyor
12. Slat conveyor
13. Tow line conveyor
14. Trolley conveyor
15. Wheel conveyor
Gravity conveyor: - The simplest kind, gravity
conveyors feature an incline and use the force of gravity, or
of a person, to push the load along the conveyor surface.
The main types include:
Chute conveyor The most basic style, chute
conveyors feature a solid surface made of metal or plastic
that is angled down in a straight or spiral configuration. The
load slides along the surface.
Gravity roller conveyor Support a load on a series
of rollers with internal ball bearing rings mounted on axles
at fixed intervals in a frame. They come in straight, curved,
spur or merge configurations.
Gravity wheel conveyor - Ideal for light duty handling
of loads with flat, smooth bottoms, gravity wheel conveyors
support the load on a series of skatewheels mounted on a
shaft in a frame. The conveyor sections can be fixed or a
flexible, expandable accordion frame.
Powered conveyor: Driven by either an electric or
pneumatic power system, a powered conveyors movement
is driven by motors and drives. There are several types,
including:

Accumulation conveyor - A conveyor that

accumulates loads at a location. To avoid any abrupt
collisions of (or damage to) the loads, a variety of methods
are employed to slow their travel speeds. These include
non-contact, minimum pressure and zero pressure.
Belt conveyor - A powered conveyor that transports
loads on belts made of fabric, rubber, plastic, leather or
metal. Types include roller belt, slider belt and telescoping
belt.
Chain conveyor Transports of heavy unit loads
(such as pallets or containers) chain conveyors use a single
or double chain that provides the driving force to pull the
load forward.
Live roller conveyor This is the most common
conveyor used in warehousing. Loads travel on rollers
mounted in a frame and powered through various means.
Types include: belt driven and line shaft driven.
Poternoster or platform conveyor - A type of vertical
conveyor that includes multiple, equally spaced, load-
 carrying units fixed to chains that move continuously in an
endless loop. This permits automatic loading and unloading.
Slat conveyor - Utilizes one or more endless chains
that have non-overlapping, non-interlocking, spaced slats
attached. Loads ride on the slats.
Vertical reciprocating conveyor (VRC) : For
transferring a load from one level to another, VRCs feature
a carrier that moves up and down to carry materials or
objects from one belt or roller conveyor to another. They
can be power or gravity actuated, and can operate
automatically or manually. There are three styles:
Two post cantilever lift - Featuring a carriage guided
and supported by two masts on the same side so three
sides can be accessed to accommodate C-, Z- or 90-
loading.
Two post straddle lift Featuring a carriage is
guided by and suspended between two masts located on
opposite sides of the carriage for C- and Z-loading.
Four post lift A type of straddle lift carriage guided
by and suspended between two sets of two masts located
on opposite sides of the carriage for higher capacity use.
They accommodate C-, Z- or 90-loading.
B. Palletizer
These are high-speed automated equipment to palletize cotainers
coming off production or assembly lines. With operator-friendly
touch-screen controls, they palletize at the rate of a hundred cases
per minute, palletize two lines of cases simultaneously, or
simultaneously handle multiple products.
C. Trucks
Trucks are particularly useful when the material moved varies
frequently in size, shape, and weight, when the volume of the parts
or material moved is low and when the number of trips required for
each part is relatively small.
Some kind of trucks
1. Hand truck
2. Fork lift truck
3. Pallet truck
4. Platform truck
5. Counter-balanced truck
6. Tractor-trailer truck
7. Automated guided vehicles (AGV)
8. Pallet Jack
9. Walkie Stacker
10. Narrow Isle Reach Truck
11. Turret Truck
12. Order Picker
13. Sideloader
14. Personnel and burden carrier
 D. Robots
These are programmable devices that resemble the human arm.
They are also capable of moving like the human arm and can
perform function such as weld, pick and place, load and unloadd.
E. Automated Guided Vehicles
The first system was installed in 1953. They can be regarded as a
typed of specially designed robots.
i. Automated carts - The simplest kind of AGV with minimal features
for lowest cost implementation.
ii. Unit load AGVs - Individual vehicles that transport loads (typically
pallets, bins, carts or bundles) on forks or on the AGVs deck. Roll-
handling AGVs specifically handle heavy rolls of steel or paper.
iii. Tugger AGVs Powered units pulling a series of non-motorized
trailers that each carries a load.
iv. Automated forklift AGVs - An existing forklift truck whose controls
have been converted to allow unmanned operation
F. Hoist, Cranes, and Jobs
These MHDs are preferred when the parts to be moved are bulky
an require more space for transportation. The movement of
material in the overhead space does not affect production process
and worker in a factory.
G. Warehouse Material Handling Devices
Theres are typically referred to as storage and retrieval systems. If
they are automated to a high degree, they are referred to as
automated storage and retrieval systems (AS/RS) The primary
functions of warehouse material handling devices are to store and
retrieve materials as well as transport them between the
pick/deposit (P/D) stations and the storage locations of the
materials.
AS/RSs are capital-intensive systems. These are low-labor and
energy cost, high land r space utilization, high reliability and
accuracy and high throughput rates.
H. Autonomous Vehicle Storage and Retrieval System
These represent a relatively new technology for automated unit
load storage systems.
VI. How to Choose the Right Equipment
The material handling equation can be specified as:
Material + Move = Method.
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BULK MATERIAL HANDLING EQUIPMENT
 Bulk material handling refers to the storing, transportation and control of
materials in loose bulk form. These materials can include food, liquid, or
minerals, among others. Generally, these pieces of equipment deal with the
items in loose form, such as conveyor belts or elevators designed to move
large quantities of material, or in packaged form, through the use of drums
and hoppers.
a. Conveyor Belt
b. Stackers
c. Reclaimers
d. Bucket Elevators
e. Grain Elevators
f. Hoppers
g. Silo
VIII. CONTAINERS AND UNITIZING EQUIPMENT
Manual
Manual unitizing involves little in the way of equipment and is done by hand. In this
application, a worker moves around the load holding the handles of a roll of film,
unrolling, applying and wrapping the product as they circle. Strapping, or banding, can
also be applied to a load manually using a handheld device that cuts and secures the
straps.
Manual unitizing can be cost effective in a very slow speed process, but its not
commonly used in most industrial environments, explains Hayes. However, there are
always exceptions. Products that are unusual in shape and size, such as curtain rods,
doors and siding, are good candidates for manual unitizing
Semi- and fully automatic equipment
An operation that unitizes more than 15 loads per day can likely justify some level of
automation based on savings in labor, back strain and unitizing material costs.
In a semi-automatic unitizing operation, some degree of worker involvement is required.
This could mean that an operator delivers a pallet load of product by lift truck to the
unitizing equipment or has a hand in applying, guiding and detaching the binding
material during the process.
In a fully automatic operation, product is delivered to the unitizing equipment by
conveyor. The four main types of in-feed conveyor include roller, belt, chain and walking
beam. Walking beam conveyor is typically used when moving very heavy duty, durable
product such as concrete blocks and bricks. Roller or belt conveyor are best when there
are no pallets carrying the load; roller or chain conveyor work well with pallets.
Stretchwrapping is the most common way to unitize a load. Stretchwrapping equipment
can range in price and in sophistication, from semi-automatic turntable models to fully
automatic rotary arm or rotary ring models with automatic programming. A semi-
automatic stretchwrapper needs an operator to tie the film to the load before wrapping
begins and to cut the film after wrapping is complete.
STRETCHWRAPPING SYSTEM
Fully automatic stretchwrapping systems attach and cut the film without human
intervention.
Most systems use photoelectric eyes to detect loads, so an operator is not needed in
the process. These systems are best suited for routine operations where the same
product comes down a conveyor line many times a day.
A number of stretchwrapping machines are available. For example, platform, or
turntable, style equipment spins the load as it is being wrapped. These machines are
the least expensive and slowest, wrapping 40 to 50 loads per hour.
Stretch hooding and shrinkwrapping
This law of physics also applies when unitizing a load with stretch hooding. With this
method, the unitizing equipment stretches a hood or bag over a load, which then
contracts back to its original size once in place.
Like stretch hooding, shrinkwrapping also uses a bag to unitize the load. In this
process, however, an over-sized bag is placed over the load then heated to shrink
around the load. Heat can be applied to the load manually with a heat gun or the load
can move by conveyor through a heat tunnel to shrink the material.
Both stretch hooding and shrinkwrapping use only a single layer of binding material
which lends itself to easy bar code scanning. Another advantage is that both methods
provide product protection on five sides of the load, which is a key factor if product is
going to be stored outdoors.
Strapping
Strapping is a good option for a variety of products where surface protection is not the
primary concern, says Mark Hughes, manager of application development and research
for Signode.
Strapping can be applied to a load by hand using manual and pneumatic tools, or using
semi-automatic or fully automatic strapping machines that include strapping heads that
unroll the materials as needed.
The straps joining method is dependent on the type of strap and the joint strength
required by the application as well as the equipment being used to apply the strap,
says Hughes. In some manual hand tool applications, plastic strapping is joined by
using metal seals and special sealers to form crimp joints. Crimp joints are formed by
compressing the seal onto overlapping straps. The holding power of the joint is
generated by squeezing the straps and the seal together.
Strapping materials include steel and plastic, with plastic having a number of benefits.
According to Hughes, plastic strapping has excellent elongation and recovery
characteristics, stays tight and absorbs impacts without breaking. Its also safer to
handle than steel and reduces indentation at unprotected package corners.

Cornerboard
As its name implies, cornerboard can protect product corners by adding a strong, hard
edge to the load. It also serves to support the load, add stacking strength and improve
load stability during transit. Cornerboard, which comes in 90-degree angle strips of a
variety of materials, can be sized for the demands of the environment and task required.
Cornerboards can be a good option any time you have layers of small boxes (think of a
pallet of strawberry bins) that when stacked are not stable, says Pat Fitzgerald, new
market development manager for ITW Angleboard. At the same time, cornerboards
provide significant benefits when shipping lumber, plastics, metal, furniture, appliances
and other products that need edge protection from strapping that secures the unit or
simply from transit induced damages.
In the majority of cases, says Fitzgerald, cornerboards are hand-applied to loads;
however, there are automatic wrapping machines that apply the protective product
automatically to the load and then secure it in place with stretch film.
Greener unitizing
Over the last decade unitizing machines have evolved in performance, speed and
quality, says Wulftecs Lopes. Todays machines are more durable than they were 10
years ago. Were seeing better construction and better choices in components across
the industry.
One of the most recent enhancements is the introduction of sensors and computer logic
that optimize the machines energy usage. These new tools are able to look at the
product coming into the machine and determine whether or not theres a backlog. If
there is a backlog, the machine runs fast, if theres no backlog, it runs at a slower,
energy-efficient speed.
References:
http://www.thomasnet.com/articles/materials-handling/material-handling-equipment
http://www.mhi.org/fundamentals/automated-storage
http://www.mhi.org/fundamentals/automatic-guided-vehicles
http://www.mmh.com/article/equipment_101_unitizing_equipment