Custom Material Handling Systems for Manufacturers

Material handling systems are the equipment, controls, and processes used to move, store, protect, and position materials throughout manufacturing or distribution. In an automated setting, they may include industrial robots, conveyors, pallets, racks, fixtures, sensors, vision systems, end-of-arm tooling, and safety systems. Their purpose is to keep materials flowing reliably between production steps while supporting throughput, quality, and worker safety.

Material handling means moving, storing, controlling, and protecting raw materials, work-in-process, components, and finished goods. In manufacturing, it covers the movement of parts between machines, workstations, assembly cells, inspection stations, and shipping areas. Robotic material handling automates repetitive moves, such as picking parts from bins, loading machines, transferring products, or stacking finished goods on pallets.

MHE, or material handling equipment, commonly includes forklifts, conveyors, pallet jacks, racks, lifts, cranes, automated guided vehicles, autonomous mobile robots, palletizers, and industrial robots. In robotic manufacturing cells, MHE can also include grippers, vacuum tooling, fixtures, sensors, safety guarding, and vision systems. The right mix depends on the part size, weight, orientation, travel path, volume, and required cycle time.

The main material handling methods are manual handling, mechanized handling, automated handling, and semi-automated handling. Manual handling relies on people and simple tools; mechanized methods use equipment such as forklifts or hoists; automated methods use robots, conveyors, controls, and sensors; and semi-automated approaches combine operators with automated equipment. Manufacturers often use several methods together to balance flexibility, safety, and throughput.

Robots are especially effective for repetitive, predictable tasks with defined pick and place locations, high volumes, ergonomic risks, or demanding cycle times. Common applications include palletizing, depalletizing, bin picking, machine loading, racking, de-racking, conveyor transfers, and part presentation for welding or assembly. Vision guidance can expand automation to parts that arrive in variable positions or orientations.

Yes. A custom system can be designed to interface with existing conveyors, CNC machines, presses, molding equipment, racks, fixtures, and plant controls. Integration planning evaluates communication protocols, part presentation, available footprint, guarding, upstream and downstream timing, and operating states. GLOBAL’s controls engineering and PLC integration capabilities help connect the robotic cell to the broader production process while maintaining safe, coordinated operation.

A useful project scope starts with part drawings or samples, weights and dimensions, required cycle time, expected production volume, current process flow, available floor space, and machine or conveyor details. It is also important to identify part variability, surface sensitivity, orientation requirements, safety expectations, and quality checks. Process analysis and feasibility work can turn that information into a practical concept, timeline, and return-on-investment assessment.

Implementation timing varies with the application’s complexity, equipment lead times, tooling, controls interfaces, safety requirements, and site readiness. A complete project typically progresses through process review, concept development, design, simulation, build, factory validation, installation, commissioning, and training. Early feasibility analysis helps clarify the project scope and identify integration constraints before a manufacturer commits to a full production system.