Types of Material Handling Equipment: The Four Categories Explained
Material handling equipment (MHE) is any machine used to move, store, control, or protect materials through manufacturing, warehousing, and distribution. It is divided into four categories: storage and handling, industrial trucks, bulk handling, and engineered systems. Selecting the right equipment means matching the category to the material, the load, and the facility, then confirming the safety standard that governs it.
This guide explains the four categories, the main equipment in each, and the standards and specifications that drive selection. It is written for operations, MRO, and procurement teams specifying material handling equipment for a plant, warehouse, or distribution center.
The four categories of material handling equipment
Material handling equipment falls into four categories, each addressing a different stage of material movement. The table maps them, and the detail follows.
Category
Function
Example equipment
Storage and handling
Hold and organize inventory
Pallet racks, shelving, mezzanines
Industrial trucks
Move loads horizontally and lift
Forklifts, pallet jacks, order pickers
Bulk handling
Move loose bulk materials
Conveyors, bucket elevators, hoppers
Engineered systems
Automate movement and storage
AS/RS, AGVs, conveyor systems
Storage and handling equipment
Storage and handling equipment holds and organizes inventory, using vertical space to maximize capacity. It includes pallet racks, cantilever racks, shelving, and mezzanines, and it is governed for steel racking by ANSI MH16.1, the RMI standard for industrial steel storage racks.
Pallet racking is the backbone of most warehouses, and selection starts with the floor load capacity and the beam capacity per level. Confirm the rack's rated capacity against the heaviest palletized load, verify aisle width for the lift trucks that will service it, and post weight limits on every bay. Inspect uprights and beams regularly, since one damaged component can cause a rack collapse under load.
Industrial trucks
Industrial trucks move loads horizontally and lift them, and in the United States they are governed by OSHA 29 CFR1910.178, the powered-industrial-truck standard. OSHA defines seven forklift classes, with Classes I to V used in warehousing and Classes VI to VII for rough terrain.
A counterbalance forklift uses a rear counterweight to offset front loads and suits dock loading and wider aisles. A reach truck extends its forks into racking and operates in aisles as narrow as 1.5 to 2.5 meters, enabling denser storage. Standard warehouse forklifts handle loads up to about 5,000 pounds and lift 10 to 15 feet, while walkie stackers carry 2,000 to 4,000 pounds.
Match the truck's rated capacity to the heaviest load, not the average, and match tire type to the surface: cushion tires for smooth indoor floors, pneumatic for uneven outdoor ground. OSHA requires certified operator training before anyone operates a powered industrial truck.
Bulk material handling equipment
Bulk material handling equipment moves and stores loose materials such as grain, coal, ore, and aggregate. It includes conveyors, bucket elevators, hoppers, silos, stackers, and reclaimers, and conveyor safety is governed by ASME B20.1.
Bucket elevators lift bulk materials vertically in an enclosed system, common in agriculture and mining. Hoppers and silos provide large-volume storage with controlled discharge, while stackers and reclaimers manage stockpiles. Select bulk equipment by the material's density, flow characteristics, and throughput, and confirm the conveyor guarding meets ASME B20.1 before commissioning.
Engineered systems
Engineered systems are automated equipment that move and store materials with minimal manual labor. The main types are automated storage and retrieval systems (AS/RS), automated guided vehicles (AGVs), and powered conveyor systems.
AS/RS automatically place and retrieve loads from dense storage, maximizing throughput and accuracy in high-volume operations. AGVs are mobile robots that follow fixed guide paths, while the newer autonomous mobile robots (AMRs) navigate dynamically without fixed infrastructure. Powered conveyor systems move product continuously for sorting, accumulation, and transport. Select engineered systems by throughput, payload, and how much the facility layout can change.
How to select material handling equipment
Selecting material handling equipment is a matching exercise across five factors. The table summarizes them, and the sequence below applies them.
Factor
What to confirm
Load
Weight, dimensions, and load center
Facility
Aisle width, ceiling height, floor capacity
Throughput
Units or tones moved per hour
Environment
Indoor, outdoor, temperature, hazard class
Compliance
OSHA, ASME, or ANSI standard for the type
Start from the load weight and dimensions, then confirm the facility constraints of aisle width, ceiling height, and floor load capacity. Set the required throughput, verify the operating environment, and confirm the governing safety standard. Sizing to the heaviest load and the tightest aisle, not the average, is what prevents both safety incidents and costly re-specification.
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Frequently asked questions
What are the four categories of material handling equipment?
The four categories are storage and handling equipment (racks, shelving), industrial trucks (forklifts, pallet jacks), bulk material handling equipment (conveyors, bucket elevators, hoppers), and engineered systems (AS/RS, AGVs, conveyor systems). Each addresses a different stage of moving, storing, and controlling materials through a facility.
What is material handling equipment?
Material handling equipment (MHE) is any mechanical, automated, or manual device used to move, store, protect, and control materials through manufacturing, warehousing, and distribution. Examples include forklifts, pallet racks, conveyors, and automated storage and retrieval systems. It improves efficiency, accuracy, and safety while reducing manual labor.
What OSHA standard governs forklifts?
Forklifts, which OSHA calls powered industrial trucks, are governed by OSHA 29 CFR 1910.178. The standard defines seven forklift classes and requires that operators be trained and evaluated on the specific type of truck they operate. Classes I to V are used in warehousing, and Classes VI to VII are for rough terrain.
What is the difference between a counterbalanced forklift and a reach truck?
A counterbalance forklift uses a rear counterweight to offset front loads and works in wider aisles and dock loading. A reach truck extends its forks forward into racking and operates in aisles as narrow as 1.5 to 2.5 meters, enabling denser storage. Choose counterbalance for versatility and reach trucks for high-density warehouse storage.
What is the difference between an AGV and an AMR?
An automated guided vehicle (AGV) follows a fixed path defined by wires, magnets, or floor markings. An autonomous mobile robot (AMR) navigates dynamically using onboard sensors and mapping, without fixed infrastructure. AGVs suit stable, repetitive routes, while AMRs suit flexible layouts and changing workflows.
How do I choose the right forklift capacity?
Match the forklift's rated capacity to the heaviest load you will lift, not the average, and account for the load center distance. Standard warehouse forklifts handle up to about 5,000 pounds and lift 10 to 15 feet. Confirm tire type for the surface and verify the lift height reaches your top rack level safely.
What standards apply to warehouse racking and conveyors?
Steel storage racking is governed by ANSI MH16.1, the Rack Manufacturers Institute standard, and conveyor safety by ASME B20.1. Both define design, load rating, and safety requirements. Confirm the rack's rated beam and floor load capacity and that conveyor guarding meets ASME B20.1 before commissioning.
