Conveyors
Conveyors provide continuous, fixed-path movement of material. They are the most efficient method for high-volume continuous throughput but lack flexibility — path cannot be changed without capital investment.
| Type | Best for | Notes |
|---|---|---|
| Belt conveyor | Bulk materials, unit loads, inclines up to 18° | Most versatile; see our design guide |
| Chain conveyor | Heavy, hot, or sharp materials; pallet handling | High strength; suitable for high temperatures |
| Screw conveyor | Loose, powdery, or semi-solid bulk materials | Enclosed — dust and moisture control |
| Roller conveyor | Flat-bottomed unit loads (cartons, pallets) | Powered or gravity; low maintenance |
| Overhead conveyor | Assembly lines; paint lines; garment handling | Frees floor space; compatible with processes above |
| Pneumatic conveyor | Fine powders, grain, pellets over long distances | Dilute or dense phase; fully enclosed |
Hoists and Cranes
Hoists and cranes are used for lifting and positioning loads that are too heavy for manual handling. Key selection parameters: safe working load (SWL), hook height, span/reach, duty classification, and environment.
- Chain hoists (manual or electric): 125 kg to 20 t; compact; low headroom available; ideal for workshop and maintenance use. See our wire rope vs chain hoist guide.
- Wire rope hoists: 250 kg to 100+ t; high-duty cycle; faster lifting speeds; standard for production crane systems
- Overhead travelling cranes (EOT): Full-bay coverage; standard for heavy manufacturing, fabrication, and maintenance bays
- Jib cranes: 360° or 180° coverage of a limited work zone; ideal for workstation loading
- Monorail hoists: Fixed track; efficient movement on a single path; common in assembly lines
Duty classification (FEM or ISO 4301): M1 (very light, infrequent) to M8 (very heavy, continuous duty). Specifying too light a duty class causes accelerated wear and premature failure on intensive applications.
Industrial Trucks
Industrial trucks provide flexible, on-demand material movement. No fixed path — essential for warehousing, receiving, and operations with variable routings.
- Counterbalance forklift: Most versatile; handles pallets, drums, and custom attachments; 1.5–40 t capacity; electric, LPG, or diesel
- Reach truck: Narrow-aisle warehouse use; reaches into racking without turning; electric-only
- Pallet truck (manual or powered): Low-level pallet movement on flat floors; economical; highest throughput with BEV-powered walkie rider types
- Automated Guided Vehicles (AGVs): Fixed-path laser or magnetic guidance; unmanned; highest ROI in high-volume repetitive flows
Equipment Selection Criteria
| Factor | Questions to ask |
|---|---|
| Load characteristics | What is the weight, size, shape, fragility, temperature, and chemical nature of the material? |
| Throughput | What is the required throughput (tonnes/hour, units/hour)? |
| Path flexibility | Is the route fixed (use conveyor) or variable (use truck)? |
| Duty | Continuous or intermittent operation? How many hours per day? |
| Environment | Hazardous area (ATEX)? Food-grade? Extreme temperature? Outdoor? |
| Capital vs operating cost | What is the 10-year lifecycle cost including maintenance and energy? |
Maintenance Principles
All material handling equipment requires a structured maintenance programme. Key principles:
- Perform daily operator checks — fluid levels, brake, horn, lights, forks/chains
- Inspect lifting equipment thoroughly at intervals specified in the written scheme of examination (LOLER in UK)
- LOLER (Lifting Operations and Lifting Equipment Regulations 1998) requires thorough examination by a competent person — at least every 6 months for lifting persons; 12 months for other lifting equipment or per the written scheme
- Document all inspections, defects, and repairs in the equipment history record