What Is Automated Material Handling?
Automated material handling refers to the use of advanced systems, equipment, and software to move, store, control, and protect materials throughout manufacturing, warehousing, and distribution processes with minimal human intervention.
Modern materials handling systems integrate:
l conveyors and sortation systems
l automated storage and retrieval systems (ASRS)
l shuttle systems and robotic solutions
l automated guided vehicles (AGVs) and AMRs
l warehouse control software (WCS)
The goal of materials handling technology is to improve operational efficiency, reduce labor costs, and ensure smooth material flow across industrial and logistics environments.
According to industry data, the global material handling equipment market is expected to exceed $250 billion by 2030, driven by rapid growth in e-commerce, manufacturing automation, and smart logistics.
How Automated Material Handling Systems Work
An automated material handling system connects multiple technologies to manage material flow efficiently.
Core Components
Component | Function |
Conveyor Systems | Transport goods between locations |
ASRS Systems | Store and retrieve materials automatically |
Shuttle Systems | Move goods within racks |
AGVs / AMRs | Autonomous transport vehicles |
Control Systems | Manage operations and workflows |
Typical Workflow
1. Materials enter the facility through receiving stations
2. Identification systems (barcode/RFID) track inventory
3. Conveyors or AGVs transport goods
4. ASRS or shuttle systems store materials
5. Orders trigger automated retrieval
6. Materials are sorted and shipped
This process ensures continuous, efficient, and error-free material flow.
Types of Materials Handling Systems
There are several types of materials handling systems used in automated environments.
1. Conveyor-Based Systems
Conveyors are widely used for continuous material transport.
l belt conveyors
l roller conveyors
l sortation conveyors
2. Automated Storage Systems
Includes:
l ASRS systems
l shuttle storage systems
These systems provide high-density storage and automated retrieval.
3. Robotic Handling Systems
Robotics play a key role in modern automation.
l robotic arms
l palletizing robots
l picking robots
4. Vehicle-Based Systems
Autonomous vehicles transport materials across facilities.
l AGVs (Automated Guided Vehicles)
l AMRs (Autonomous Mobile Robots)
Benefits of Automated Material Handling
Increased Efficiency
Automation reduces manual handling and speeds up operations.
Metric | Improvement |
Material Flow Speed | +30–50% |
Order Fulfillment Speed | +40% |
Operational Efficiency | +25–60% |
Reduced Labor Costs
Automated systems minimize reliance on manual labor.
Improved Safety
Automation reduces workplace accidents by limiting human interaction with heavy machinery.
Higher Accuracy
Automated systems ensure accurate inventory tracking and order fulfillment.
Factor | Improvement |
Inventory Accuracy | >99% |
Error Rate | Reduced by 70% |
Automated Material Handling vs Manual Handling
Feature | Manual Handling | Automated Material Handling |
Labor Requirement | High | Low |
Efficiency | Medium | High |
Accuracy | Moderate | High |
Safety | Lower | Higher |
Automation clearly provides superior performance in modern industrial environments.
Applications of Automated Material Handling Systems
Manufacturing
l production line material flow
l assembly support
l work-in-progress handling
Warehousing
l automated storage and retrieval
l order picking
l pallet transport
E-commerce
l high-speed sorting
l goods-to-person picking
l order fulfillment
Logistics and Distribution
l cross-docking
l sorting systems
l shipping automation
Automated Material Handling Examples
Understanding real-world automated material handling examples helps businesses choose the right system for their operations.
Below are common use cases across industries.
1. ASRS Warehouse Systems
Automated Storage and Retrieval Systems (ASRS) are widely used for high-density storage.
Example:
l Pallets are automatically stored using stacker cranes
l Shuttle systems retrieve goods for outbound orders
l Inventory is managed in real time
Best for:
l manufacturing warehouses
l logistics distribution centers
2. Conveyor and Sortation Systems
Conveyor systems automate material transport between warehouse zones.
Example:
l cartons move through conveyor belts
l automated sorters direct goods to shipping lanes
Best for:
l e-commerce fulfillment centers
l parcel sorting hubs
3. Shuttle-Based Storage Systems
Shuttle systems are used for dense pallet storage and fast material movement.
Example:
l radio shuttle moves pallets inside deep lanes
l four-way shuttle transfers goods across warehouse levels
Best for:
l cold storage warehouses
l FMCG distribution
4. AGV and AMR Systems
Autonomous vehicles transport materials without human drivers.
Example:
l AGVs move pallets between production and storage
l AMRs deliver goods to picking stations
Best for:
l flexible warehouse environments
l smart factories
5. Robotic Picking Systems
Robots automate picking and packing operations.
Example:
l robotic arms pick items from bins
l goods-to-person systems deliver items to operators
Best for:
l high SKU warehouses
l e-commerce operations
Future Trends in Materials Handling Technology
Robotics and AI Integration
Automation systems are increasingly powered by AI for:
l route optimization
l predictive maintenance
l intelligent decision-making
Smart Logistics Systems
Integration with IoT enables real-time monitoring and control.
Sustainable Automation
Energy-efficient systems are becoming a priority in industrial automation.
How to Choose the Right Material Handling System
Factor | Consideration |
Material Type | Pallets, bins, or small items |
Throughput | Required processing speed |
Space | Warehouse layout |
Budget | Investment level |
Automation Goals | Efficiency vs flexibility |
Automated Material Handling Companies
Choosing the right partner is critical when investing in automated material handling systems. Many global automated material handling companies provide advanced solutions for warehouse and industrial automation.
Leading Automated Material Handling Companies
Company | Country | Core Solutions |
China | Shuttle systems, ASRS, warehouse automation | |
Daifuku | Japan | ASRS, conveyor systems |
SSI Schaefer | Germany | Shuttle systems, warehouse automation |
Dematic | USA | Integrated automation solutions |
Honeywell Intelligrated | USA | Material handling and software systems |
Vanderlande | Netherlands | Logistics automation |
How to Choose the Right Automation Company
When selecting a provider, consider:
1. Technical Capability
l experience withASRS and shuttle systems
l ability to deliver integrated solutions
2. Customization Ability
Every warehouse is different. Choose a company that can provide:
l tailored system design
l scalable automation solutions
3. Software Integration
A strong automation provider should offer:
l WMS/WCS integration
l real-time data tracking
l system optimization
4. After-Sales Support
Reliable support ensures long-term system performance.
Why HEGERLS Stands Out in Material Handling Automation
As one of the leading automated material handling companies, HEGERLS advanced automated material handling systems integrated with warehouse automation technologies.
l shuttle-based storage solutions
l conveyor and sorting systems
l intelligent warehouse control software
l intelligent warehouse automation
l full lifecycle project support
Our solutions are designed to help businesses achieve:
l higher efficiency
l lower operational costs
l scalable automation growth
Optimize Your Operations with Automated Material Handling
If your business is looking to improve efficiency, reduce costs, and enhance material flow, automated material handling systems are essential.
HEGERLS offers customized materials handling solutions tailored to your warehouse and production needs.
Our Solutions Help You:
l Increase operational efficiency by up to 60%
l Reduce labor costs significantly
l Improve safety and accuracy
l Build scalable automation systems
Request a Free Material Handling System Consultation
