• Volkan
• May 30, 2025

The Importance of Material Handling for Your Business: Your Complete Guide

Material handling systems are used throughout multiple industries to improve supply chain management, ensure products and assets are handled safely as well as optimise logistical processes. Getting the right type of automated material handling system in place that’s designed for distinct environmental conditions and unique operations will provide your business with key benefits and help you avoid common challenges. All is detailed in this guide from the material handling specialists at Coveya, presenting you with the information to understand the importance of having the right system in place for your business.

What Is Material Handling?

Material handling means moving materials and goods from one location to another, using different material handling systems which can be manual, semi-automated or fully automated. In addition to physical transportation systems, other material handling solutions include storage devices, control measures and software to optimise and manage the flow of goods.

• Manual handling – where tasks are performed by workers using physical effort
• Semi-automated systems – combine human input with machinery
• Automated handling – uses advanced systems to move materials with minimal human involvement

Some of the most common types of material handling systems include:

• Conveyors
• Pallet jacks and forklifts
• Cranes and hoists
• Automated storage and retrieval systems (AS/RS)
• Shelving and racking systems
• Trolleys and carts

From production lines to warehouses, these systems are essential for maintaining productivity, safety and cost efficiency.

Most Common Material Handling Challenges

Before delving into more detail on the variety of systems out there, it’s important to cover some common challenges businesses and sectors face when transporting materials and goods, whether it’s consumer products, construction materials, waste or aggregates. These challenges can lead to material handling inefficiencies and safety risks.

• Manual inefficiencies – relying heavily on manual labour can lead to slower processes, higher fatigue levels and increased potential for human error. The risk of worker fatigue alone can result in serious injuries and costly downtime.
• Poor layout and flow – Operational flow is crucial for successful logistics and meeting supply chain demands. A disorganised layout will create unnecessary travel distances, congestion and workflow interruptions. Poor material flow makes it challenging to locate items quickly, slows down picking and reduces overall material handling output.
• Safety risks – Safety risks can come in the form of inadequate training, improper use of equipment or even lack of clear pathways, all of which can lead to accidents. Also, frequent lifting, unguarded machinery and unmarked hazards all pose risks to both workers and operational integrity.
• Equipment that doesn’t scale – Many businesses still use outdated material handling solutions, which limit their ability to adapt to growing demand. Without systems designed for scalability, even small increases in volume can cause major delays or require costly upgrades.
• Lack of automation/integration – Without automated or integrated systems, processes become fragmented, resulting in duplicate tasks, missed data and limited visibility. Automated material handling equipment supports the opportunities many businesses miss out on, including efficiency gains, real-time tracking and smarter decision making.

Identifying any of these challenges in your business isn’t the end of the world – it’s an opportunity to improve and seek out the best, most suited material handling systems for your operations.

4 Types of Material Handling Systems

Which system for material handling is best? Well, here are five of the most used and how they function.

1. Conveyors

Conveyor belts have come a long way since their origins back in the 19th century. Part of the automated material handling range of equipment, conveyors can be set up in all manner of settings, such as warehouses, airports, construction sites, water treatment facilities and manufacturing centres.

Conveyors are made up of a continuous belt, rollers or chains that move materials from one point to another. They can handle materials horizontally, vertically and around curves, and they are ideal for high-volume environments to consistently transport goods, components or packaging materials. Conveyor belt automation helps reduce manual handling, increase efficiency and improve workplace safety by keeping materials in constant motion.

2. Forklifts and Pallet Jacks

Forklifts and pallet jacks have become a staple for material handling, lifting, moving and stacking, especially in warehouse settings. Forklifts offer powered lifting for heavy loads, enabling goods to be stacked higher on shelves, while pallet jacks are manually operated and suitable for ground-level pallet movement.

Both systems provide flexible material handling solutions in smaller spaces where precision and safety are paramount, making them indispensable in warehouses, retail operations and loading docks.

3. Robotics Systems

Innovative developments have increased dramatically due to machine learning and AI being integrated into material handling processes. Many robotic systems can assist in picking, packing, sorting and moving materials, and while they may come with a substantial initial investment, they are best utilised for more mundane, repetitive and high-volume roles.

Robotics systems also help reduce human error, minimise injury risk and enhance throughput across the supply chain. However, they also come with the responsibility of high maintenance and professional configuration.

4. Hoists and Cranes

Both these material handling systems are crucial in industries like construction, shipping and heavy manufacturing, where manual lifting simply isn’t possible. Hoists and cranes are purpose-built to lift and move heavy and oversized loads vertically and across long spans. Gantry and tower cranes are most suitable for transporting items in large facilities or outdoors, while hoists are much more suited for material handling in confined and indoor areas.

How to Assess Your Material Handling Requirement

Getting a clear understanding of your current operations will allow you to evaluate whether your current manual or automated material handling equipment is the right fit or if you need to implement new solutions. Aspects you should be monitoring include:

• Mapping your workflows
• Identifying bottlenecks
• Assessing how efficiently materials move through your facility
• Looking at equipment usage
• Monitoring staff productivity
• Analysing safety incidents

Assessing these areas will help determine what needs to improve. It may be time to upgrade your material handling systems if you’re consistently missing deadlines, struggling with equipment breakdowns or noticing a rise in manual labour costs.

Modern solutions, like conveyors or other automated equipment, are available to dramatically improve flow and reduce overheads. As a warehouse manager, manufacturer or business owner, ask yourself these questions to assess your requirements:

• Are we meeting production targets consistently?
• Where are delays happening in our process and supply chain?
• Are the current systems scalable?
• Is manual handling slowing us down or posing safety risks?

Working with the material handling specialists at Coveya can help you discover the best solution for your specific requirements. We can provide expert insight and implement the ideal conveyor equipment to streamline operations, reduce costs, enhance safety and future-proof your facility.

The Role of Conveyors In Material Handling

Conveyors are a versatile and efficient automated solution for material handling. The benefits of conveyor belt systems include lowering costs on labour and potential damage to goods, streamlining productivity with automation and, possibly most importantly, they can be designed with future expansion and changing dynamics in mind.

The different types of conveyors we can supply, design and install include:

• Belt conveyors – ideal for moving items over long distances or inclines
• Roller conveyors – best for handling flat-bottomed loads like boxes and pallets
• Overhead conveyors – used in manufacturing to move items above ground level, freeing up valuable floor space
• Screw conveyors – designed for granular or loose materials
• Chain conveyors – suited for heavy-duty items and rugged environments

When should you consider a conveyor system? Firstly, if scalability is a priority, conveyors are material handling systems that can grow with your operations. They can operate at fast speeds for managers looking to increase production and consistency. With minimal human input, safer work environments can be created, and frequent manual handling can be reduced.

Looking to Automate Your Material Handling Process? Discover Why Conveyors Are the Ideal Choice!

Discover how your business can optimise material handling with our bespoke conveyors, available to purchase or hire. With over 30 years of experience, the Coveya team can design, deliver, install and provide training on your new system. Talk to us about your requirements on 0808 169 5982 or send your details to support@coveya.co.uk.