Optimizing Warehouse Efficiency: How Tuggers, Casters, and Carts Drive Mobility and Productivity

Moving the Goods: Powering Mobility in the Warehouse

High-pressure warehousing environments need equipment that can tough it out amid fast-paced, ever-changing conditions. As the industry adopts more automation, robotics and other advanced technologies, the need for tuggers, casters and carts that can “keep the wheels rolling” on the warehouse or DC floor is also accelerating. This equipment category also supports the more mobile, modular workflows that most companies are striving for right now.

Demand for tuggers that can pull multiple carts, casters that ensure smooth navigation on uneven surfaces, and carts used for everything from transferring inventory to order picking are all in high demand. Kevin Ledversis, vice president of sales at Newcastle Systems, says that as companies create more “flexible” workspaces for employees—and work to optimize their existing space—moveable equipment has moved into the spotlight.

“If you bolt equipment to the floor, you lose all of that flexibility,” says Ledversis. Mobility also comes into play for companies that want to get more out of their existing warehouse or DC space—yet another reason why having “things on wheels” is a core focus for these operations.

He points out:

“Even if a company makes its own equipment, it still needs casters to make those items moveable.”

Reducing the number of steps an employee has to take to complete a task is another core focus, and it’s another area where carts, tuggers and/or casters can help. By putting the tools that workers need to do their jobs on wheels, for example, companies can optimize floor space and labor forces in one fell swoop.

Ledversis said:

“It’s about reducing the number of trips that someone has to take back and forth on a shift, particularly for tasks where decision-making is required for example, reviewing and making a decision on warehouse management system data.”

Creating Systems that Solve Problems

Kyle Smart, sales manager, emerging technology, Yale Lift Truck Technologies, says the company is seeing an “upward trend” in the tow tractor market this year.

Some of that momentum is being driven by interest in the automated tow tractor segment, which in turn has been pushed forward by advancements in automated technology.

“Aside from the obvious factors that are affecting the workforce—availability of labor, retention and training of that workforce—the fact is tow tractors that use technology in an automated fashion can do much more than a non-automated tow tractor can,” Smart explains. By combining those advanced tractors with different types of carts and trailers, companies can create comprehensive systems to manage various tasks within the warehouse.

“We’re at a point where individual tuggers and carts aren’t really ‘separate’ anymore,” he adds. “It’s really a system that’s designed around an application and a problem.” Aside from labor, one of the biggest issues companies are dealing with right now are space constraints. With space at a premium and e-commerce order volumes continuing to climb, organizations want to optimize existing space while also managing budget constraints and an ongoing labor shortage.

To meet these goals, Smart says companies are seeking solutions that “support the growth of automation,” at whatever level of automation the company may be at currently or striving for.

For example, he says Yale offers tuggers that feature semi-autonomous safety mechanisms that can be “grown into a fully autonomous solution,” at the customer’s request. He says companies also want sustainable solutions that help them meet their ESG goals, and notes that automated systems tend to “mitigate the wear, tear and damage” on vehicles, effectively extending their useful lives.

Automation is a Driving Force

Automation continues to be a major focus in the caster manufacturing market, and it’s an area where caster manufacturers are fielding a lot of requests for products to be used with various types of automation solutions. In essence, casters have become a core “component part” of those broader automation systems.

Mark Lippert, president at Hamilton Caster, says the company has received a “record number” of requests for drive wheel applications, including treaded wheels made with keyways for use on driveshafts. In nearly all cases, these types of wheels are slated for use in some kind of machinery or automation.

Lippert says companies are also interested in safety and ergonomics, both of which have become table stakes in the fulfillment environment. “In the past, these issues were of most concern to safety managers at very large companies that had mature operations,” Lippert explains. “Now, safety and ergonomics are common themes that come up pretty much across the board.”

For example, companies are requesting more toe guards that protect workers’ feet as they operate carts. Comprised of metal frames that are welded around the caster, toe guards keep wheels from rolling over a user’s toes and/or feet. “Toe guards are more and more becoming part of the minimum startup and maintenance requirements for casters,” says Lippert.

Equipment manufacturers are also innovative and coming up with new product options, some of which surpass more “legacy” products in terms of performance and durability. For example, Hamilton Caster has formulated polyurethane treads that don’t force companies to give up durability and longevity in exchange for better rollability. Lippert says a new line of upcoming products will feature the same durability performance and rollability characteristics of a high-ergonomic wheel.

These and other changes are being made in the name of better safety, ergonomics and performance across a broad range of operational settings. “It’s all about reducing injuries, addressing fatigue and ultimately having the worker clock out at the end of the day not feeling as tired and worn out,” says Lippert. “That’s ultimately what we’re after here.”

Optimizing Every Square Foot

Tuggers, casters and carts all serve as invaluable assets in a work environment where every square foot of space and minute of labor has to be optimized. Add a persistent warehouse labor shortage, budget cuts and a booming e-commerce market to the mix, and it’s easy to see why companies are putting more effort into developing highly mobile, automated solutions supported by this specific warehouse equipment category.

Asked what trends his company is seeing in the tuggers, carts and casters product category right now, Jeff Stutz, sales manager at Cannon Equipment, says warehouse employees are moving heavier loads than ever before on carts throughout the facility as clients seek to gain labor efficiencies. As a result, demand for powered carts and power-assist technology for carts is growing exponentially in the marketplace.

Also, companies that supply dry goods to big box retailers and to grocery stores are avidly exploring and implementing the direct-store-delivery model.

Says Stutz:

“Carts are a perfect solution for this scenario as they can be used to transport goods to the retailer and rolled onto the sales floor where the associate then stocks the shelves. This process ensures a fresh, quality product for the consumer and allows the dry goods vendor to neatly and accurately stock their product on the shelves.”

In assessing the core value that tuggers, carts and casters continue to offer in the modern warehousing environment, Stutz says these materials handling products provide value in numerous ways. Not only do they improve ergonomics for associates, reduce physical strain and minimize the risk of injury, but they also help boost productivity and job satisfaction.

Stutz explains:

“They also can minimize product damage during transportation, ensuring goods reach their destination intact. These benefits contribute to a more efficient, safe and sustainable warehousing operations.”

Making Their Jobs a Little Easier

Looking ahead, Smart expects equipment manufacturers to continue infusing more automation and technology into both tuggers and carts. He also expects demand for tuggers and carts to continue as warehouse and DC operations look for new ways to optimize and modernize their existing facilities.

He predicts:

“Advancements in technology will [enable] more dynamic environments to be navigated and to ultimately be automated. The current market data is showing a pretty significant increase over the next four to five years in the tugger market, specifically.”

Ledversis expects ergonomics to continue playing an important role in companies’ plans going forward, namely in terms of giving employees the tools they need to perform tasks safely and ergonomically. Warehouse jobs are plentiful, after all, and candidates generally have multiple options to select from.

Newcastle Systems is also getting more requests for lighter, longer-lasting batteries that don’t need to be charged as often. “Companies also want products that are easier to use and feature adjustable screens, keyboards and other tools,” says Ledversis, “and all in the name of finding ways to help make someone’s job a little bit easier.”