In today’s fast-paced supply chain environment, warehouse efficiency is more critical than ever. From order fulfillment to product storage and internal transport, every movement within a warehouse impacts productivity, labor costs, and customer satisfaction. One of the most effective ways to optimize these workflows is by incorporating custom material handling carts. Material handling for warehouses is Salco’s bread and butter. Read on to learn more.
The Role of Material Handling in Modern Warehousing
Warehouses serve as critical hubs for storage, sorting, inventory management, and distribution. These facilities must maintain a continuous flow of materials to meet production schedules and delivery deadlines. At the core of that flow is material handling—the movement, protection, storage, and control of goods throughout the facility.
Material handling includes:
- Unloading shipments
- Staging work-in-process inventory
- Picking and packing orders
- Transporting parts to and from storage
- Preparing items for shipping
Improving these processes starts with having the right tools—and custom warehouse carts are among the most impactful.
Common Material Handling Challenges in Warehouses
While every warehouse is different, most facilities face similar obstacles when it comes to moving materials effectively:
1. Diverse Inventory Requirements
Warehouses often manage a wide range of SKUs, from small, fragile components to oversized pallets. Standard carts are rarely optimized for this variety, increasing the risk of inefficiency and product damage.
2. Limited Floor Space
Maximizing cubic space is a must in high-density storage facilities. Bulky or ill-fitting carts can obstruct aisles or waste valuable real estate.
3. Workplace Safety Concerns
Improper lifting or maneuvering of heavy loads can lead to injuries. OSHA regulations emphasize the importance of ergonomic equipment to reduce strain and accidents.
4. The Need for Speed and Accuracy
Customer expectations demand faster turnaround times and near-zero error rates. Material handling systems must support high-speed operations without compromising safety.
How Custom Carts Solve These Challenges
Custom warehouse carts are designed with your specific processes, products, and space constraints in mind. Unlike generic solutions, these purpose-built carts optimize every movement, reduce handling errors, and improve labor productivity. Here’s how:
1. Engineered to Fit Your Inventory
Each cart can be customized to fit the size, weight, and shape of your inventory—reducing wasted space and improving load security. This is especially helpful for transporting irregular parts, bins, or tools in production facilities.
2. Designed for Space Optimization
Need carts that fit into tight aisles, under conveyor lines, or within specific racking systems? Salco’s custom carts can be designed to fit your exact footprint, maximizing operational space without compromising capacity.
3. Built with Safety in Mind
Features like ergonomic push handles, reinforced frames, locking casters, and anti-slip decking help ensure your team can move materials safely and with less physical effort. This leads to fewer injuries and greater morale on the warehouse floor.
4. Boosted Operational Efficiency
Custom carts are often engineered for **single-touch handling**, allowing employees to complete multiple tasks in one trip. Whether it’s picking multiple orders, restocking parts, or staging items for shipping, fewer movements mean faster workflows.
Types of Custom Carts for Warehouse Operations
Salco designs and fabricates a wide range of carts to support specific warehouse functions. Here are a few of the most popular options:
1. Order Picking Carts
These carts are ideal for fulfillment centers and distribution hubs. Configurations may include adjustable shelving, storage bins, and barcode holders. Custom designs support batch picking, wave picking, and zone-based fulfillment strategies.
2. Material Transport Carts
Used for moving raw materials, WIP (work-in-process) items, or finished goods, these heavy-duty carts are built to handle large or heavy loads safely. Add-ons like side rails, tow bars, or integrated drip trays (for fluid-containing items) can be included.
3. Mobile Storage Carts
Perfect for flexible storage needs, these carts include shelving, drawers, or bins that can be easily moved throughout the warehouse. Custom layouts improve accessibility and inventory visibility.
4. Specialty Carts
Need something truly unique? Salco can design carts with integrated charging stations, work surfaces, protective enclosures, or fluid drainage systems—whatever your operation demands.
Benefits of Investing in Custom Warehouse Carts
- Reduced product damage through secure transport
- Improved pick rates and delivery accuracy
- Increased worker safety and comfort
- Greater inventory control and organization
- Better use of warehouse floor space
Whether you’re a manufacturer, fulfillment center, or 3PL provider, the right custom carts can help drive efficiency at every level of your operation.
Get a Quote for Custom Warehouse Carts Today
If your warehouse is ready to take material handling to the next level, Salco Engineering & Manufacturing can help. Our team will work with you to design and build carts that match your exact specifications—improving throughput, reducing costs, and supporting long-term growth.
From concept to production, we deliver carts that are rugged, reliable, and built for your environment. Whether you need a single prototype or a full fleet of carts for a new facility, we’re here to help. Contact us today to request a quote or speak with an engineer about your warehouse needs.