Materials Handling
Proper handling of palletized goods is essential for operational efficiency, worker safety, and load integrity. This section covers best practices and equipment specifications.
Handling Equipment
Forklifts
The most common equipment for pallet handling, with various types for different applications.
Types of Forklifts
| Type | Description | Typical Capacity | Best Applications |
|---|---|---|---|
| Counterbalance | Standard design with forks at the front and counterweight at the rear | 1,500-5,000 kg | General warehouse operations |
| Reach Truck | Outriggers at the front with retractable mast | 1,000-2,500 kg | Narrow aisle racking |
| Narrow Aisle Truck | Designed to operate in very narrow aisles | 1,000-2,000 kg | High-density storage areas |
| Articulated Forklift | Pivoting mast for increased maneuverability | 1,500-2,500 kg | Space-constrained operations |
| Rough Terrain | Large tires and high clearance | 2,500-6,000 kg | Outdoor and uneven surfaces |
Fork Specifications
- Standard Fork Dimensions: 100-150mm width, 30-50mm thickness
- Fork Length: Typically 1,000-1,200mm (should cover at least 75% of pallet depth)
- Fork Spacing Adjustment: Typically 200-760mm to accommodate different pallet sizes
- Load Backrest: Prevents load from shifting toward operator
Pallet Jacks
Manual and powered options for short-distance movement of palletized goods.
Types of Pallet Jacks
| Type | Lifting Mechanism | Typical Capacity | Best Applications |
|---|---|---|---|
| Manual | Hand pump hydraulic | 2,000-3,000 kg | Short movements, light loads |
| Electric | Battery-powered hydraulic | 1,500-3,000 kg | Medium distances, frequent use |
| Scissor Lift | Manual or electric with vertical lift | 1,000-1,500 kg | Loading/work stations |
| All-Terrain | Larger wheels for rough surfaces | 1,000-2,500 kg | Outdoor use, uneven surfaces |
Key Specifications
- Fork Length: Typically 1,150mm
- Fork Width: 160-180mm
- Minimum Fork Height: 75-85mm
- Maximum Fork Height: 190-210mm for standard, up to 800mm for high lift
Automated Systems
Modern warehouses increasingly use automated systems for pallet handling.
Types of Automated Systems
- Automated Guided Vehicles (AGVs): Self-guided vehicles
- Autonomous Mobile Robots (AMRs): AI-powered navigation
- Automated Storage and Retrieval Systems (AS/RS): Fixed systems for pallet storage/retrieval
- Pallet Shuttle Systems: Semi-automated dense storage
Key Considerations
- Pallet Quality Requirements: Automated systems typically require higher quality pallets with consistent dimensions
- Standardization: Generally require standardized pallet sizes
- Sensors and Controls: How systems detect and manipulate pallets
- Integration: Connection with warehouse management systems
Handling Techniques
Safe Lifting Practices
- Load Assessment: Evaluating weight and stability before lifting
- Fork Positioning: Properly centering forks under the pallet
- Entry Angle: Approaching pallets squarely
- Lifting Height: Minimizing lift height during transport
- Visual Clearance: Maintaining sightlines during operation
Stack Building
- Interlocking Patterns: For improved stability
- Column Stacking: When load integrity is paramount
- Height Limits: Based on pallet type and load characteristics
- Weight Distribution: Heavier items at the bottom
- Overhang Management: Minimizing product overhang
Transport Considerations
- Load Securing: Use of stretch wrap, strapping, or dunnage
- Vehicle Loading Patterns: Optimizing weight distribution
- Vibration Mitigation: Techniques to reduce in-transit damage
- Weather Protection: Measures for outdoor transport
Common Handling Issues
Pallet Damage Causes
| Issue | Cause | Prevention |
|---|---|---|
| Fork Impact Damage | Improper fork entry | Driver training, approach guides |
| Split Deck Boards | Overloading or uneven loading | Proper weight distribution, correct pallet selection |
| Broken Stringers | Excessive side force during handling | Proper handling techniques, reinforced pallets |
| Loose Nails/Fasteners | Repeated impact or poor initial quality | Quality inspection, proper handling |
Load Shifting
- Causes: Improper wrapping, sudden stops, uneven loading
- Prevention: Proper securing techniques, driver training
- Stabilization Methods: Stretch wrap patterns, corner boards, strapping
Equipment-Pallet Compatibility
- Entry Clearance Issues: Ensuring adequate space for fork entry
- Weight Capacity Matching: Aligning equipment capabilities with load requirements
- Dimension Compatibility: Ensuring handling equipment can accommodate pallet sizes
Specialized Handling Requirements
Temperature-Controlled Environments
- Cold Storage Considerations: Material changes in low temperatures
- Freezer Operations: Special handling procedures below freezing
- Hot Environment Impacts: Effects on plastic pallets and some treatments
Cleanroom and Hygienic Environments
- Contamination Prevention: Protocols for sensitive environments
- Cleaning Procedures: Pallet sanitization methods
- Material Restrictions: Suitable pallet materials for clean environments
Hazardous Materials
- Regulatory Requirements: Special handling of dangerous goods
- Containment Features: Spill control measures
- Material Compatibility: Ensuring pallets won't react with contents
- Documentation: Required handling instructions and hazard information
Training and Safety
Operator Training
- Certification Requirements: Industry and regulatory standards
- Practical Training Components: Hands-on skills development
- Assessment Methods: Evaluating operator competence
- Refresher Training: Maintaining safe handling practices
Safety Protocols
- Pre-Operation Inspection: Equipment and load checks
- Environmental Assessment: Evaluating the handling area
- Communication Procedures: Signals and coordination
- Emergency Response: Procedures for incidents
Ergonomics
- Manual Handling Limits: Maximum weights for manual manipulation
- Proper Technique: Body positioning for manual handling
- Work Height Optimization: Adjusting pallet heights to reduce strain
- Equipment Design Features: Ergonomic controls and access
Handling Efficiency
Workflow Optimization
- Travel Path Planning: Minimizing movement distances
- Handling Zones: Designated areas for specific activities
- Traffic Management: Systems to prevent congestion and delays
- Scanning and Tracking: Integrating data capture into handling
Equipment Selection Criteria
- Application Assessment: Matching equipment to specific needs
- Cost-Benefit Analysis: Comparing manual vs. powered options
- Total Cost of Ownership: Looking beyond purchase price
- Flexibility vs. Specialization: Balancing versatile and dedicated equipment