Mechanical Engineering Department
Material Handling
Engr. Edward Henrick H. Aguda, [Link]., PME
Faculty of Engineering, University of Santo Tomas
Shoes Cars Pen Electronics Linen
Medicine Utensils Mobile Phones Oven Fan
“They are all MANUFACTURED”
NATURAL RESOURCES
Ores, Coals, Oil, Natural Gas, Trees, Water
FLOW OF MANUFACTURING GOODS
Mining Manufacturing Assembly
Getting the natural Transforming natural System to combine
resources resources to products products
Material Handling
Moving the resources
MATERIAL HANDLING
is the art and science associated with the movement,
storage, control, and protection of goods and materials
throughout the process of their manufacture, Consumers
distribution, consumption, and disposal.
Material
Handling
What? SKU?
Best Where? JIT?
Solution How? AGV?
Possible When? RFID?
Engineers Why? MFA?
FLOW OF MANUFACTURING GOODS
Material Handling Equipment Logistics
Refers to the activities of the flow within a facility Refers to the management of the flow
RAW POWER, HP, kW Efficiency
MATERIAL HANDLING EQUIPMENT
refers to a range of devices and systems used to facilitate the movement,
protection, storage, and control of materials or products throughout a facility or
supply chain. These tools are essential for improving efficiency, safety, and
accuracy in material handling operations.
MATERIAL HANDLING EQUIPMENTS
refers to a range of devices and systems used to
facilitate the movement, protection, storage, and control
of materials or products throughout a facility or supply
CONVEYOR
chain
SCREW
PRESS
RADIAL
PUMP
LOGISTICS
Logistics is a broader concept that encompasses the entire process of planning, implementing,
and controlling the efficient flow and storage of goods, services, and related information from
the point of origin to the point of consumption. It includes the management of material handling,
transportation, inventory, warehousing, and distribution.
ESSENCE MATERIAL HANDLING
Most
Priority
1. Efficient and safe movement of
materials to the desired place.
2. Timely movement of the materials
when needed.
3. Supply of materials at the desired
rate.
IE / ME Engineers
4. Storing of materials utilizing
minimum space. Best Solution
Possible
5. Lowest cost solution to the materials
handling activities Least
Priority
WHAT MH ACHIEVES
1. Cut down indirect labour cost.
2. Reduce damage of materials during storage
and movement.
3. Maximise space utilization by proper storage
of materials
4. Improve customer services by supplying IE / ME Engineers
materials in a manner convenient for
handlings Efficiency
=
5. Increase efficiency and saleability of product
Profit
Product Total Movement
PRODUCT
Characteristics Quantity Sequences
Required Manual
Physical Timing / Machinery
Required
Chemical Rate
Load Sensitivity
What? 10000 qty, 80kg bag of cement
Why? Client needs
Where? Storeroom to Industrial Truck
When? Once Week, Every Morning until 5pm
How? Manual Method
Who? Four Workers 6000 week, 5million
MATERIAL HANDLING EQUATION
WHAT WHY WHERE WHEN HOW WHO
+ =
MATERIALS MOVES METHODS
MATERIAL HANDLING PRINCIPLES
are fundamental guidelines used to design and manage
the efficient movement, protection, storage, and control of
materials and products throughout the manufacturing,
warehousing, distribution, consumption, and disposal
processes.
1. PLANNING PRINCIPLE
A plan is a prescribed course of action that is defined in
advance of implementation. In its simplest form, a
material handling plan defines the material (what) and
the moves (when and where); together they define the
method (how and who).
“The plan should be developed in consultation
between the planner and all who will use and
benefit from the equipment to be employed”
Stakeholder Meetings Planning document / Method Statement
2. STANDARDIZATION PRINCIPLE
Standardization means less variety and customization in
the methods and equipment employed
Standardization applies to sizes of containers
and other load forming components as well as Less Variety = Less Complexity
operating procedures and equipment.
3. WORK PRINCIPLE
The measure of work is material flow (volume, weight, or
count per unit of time) multiplied by the distance moved.
Simplifying processes by reducing, combining, shortening
or eliminating unnecessary moves will reduce work
4. ERGONOMIC PRINCIPLE
Ergonomics is the science that seeks to adapt work or
working conditions to suit the abilities of the worker.
Equipment should be selected that eliminates
repetitive and strenuous manual labor and which
effectively interacts with human operators and users
5. UNIT LOAD PRINCIPLE
A unit load is one that can be stored or moved as a single
entity at one time, such as a pallet, container, or tote,
regardless of the number of individual items that make up
the load.
Less effort and work is required to collect and move
many individual items as a single load than to move
many items one at a time.
6. SPACE UTILIZATION PRINCIPLE
Space in material handling is three-dimensional and
therefore is counted as cubic space.
In storage areas, the objective of maximizing storage
density must be balanced against accessibility and
selectivity.
7. SYSTEM PRINCIPLE
A system is a collection of interacting and/or
interdependent entities that form a unified whole.
Inventory levels should be minimized at all stages of “Just in time”
production and distribution while respecting a management strategy that aligns raw-material orders
considerations of process variability and customer service. from suppliers directly with production schedules
8. AUTOMATION PRINCIPLE
Automation is a technology concerned with the application of electromechanical
devices, electronics, and computer-based systems to operate and control
production and service activities. It suggests the linking of multiple mechanical
operations to create a system that can be controlled by programmed instructions
Computerized material handling systems should be considered
where appropriate for effective integration of material flow and
information management.
9. ENVIRONMENTAL PRINCIPLE
Environmental consciousness stems from a desire not to
waste natural resources and to predict and eliminate the
possible negative effects of our daily actions on the
environment
Containers, pallets and other products used to form and Materials specified as hazardous have special
protect unit loads should be designed for reusability when needs with regard to spill protection,
possible and/or biodegradability as appropriate. combustibility and other risks
10. LIFE-CYCLE COST PRINCIPLE
Life-cycle costs include all cash flows that will occur from
the time the first dollar is spent to plan or procure a new
piece of equipment, or to put in place a new method, until
that method and/or equipment is totally replaced.
A long-range plan for replacement of the equipment
when it becomes obsolete should be prepared.
Mechanical Engineering Department
Material Handling: WHAT
Engr. Edward Henrick H. Aguda, [Link]., PME
Faculty of Engineering, University of Santo Tomas
CLASSIFICATION OF MATERIALS
Solid, Liquid, Gas, Slurry
UNIT LOAD BULK LOAD
UNIT LOAD MATERIAL
refers to the standardization of goods or materials
into a single, manageable unit that can be easily
handled, stored, and transported. This concept is
fundamental in logistics and supply chain
management because it helps streamline
operations and increase efficiency.
Shape of unit loads
Position of C.G. of load
Mass of unit load
Volume per unit
Type of material
Geometrical shape
Specific physical and chemical
properties
Loads sensitive
BULK LOAD MATERIAL
refers to a large quantity of material that is not
packaged into individual units but is handled in a
loose, unpackaged form. This approach is often
used for materials that are not practical to handle
individually.
Lump-size
Bulk Weight
Specific Weight
Moisture Content
Abrasiveness
BULK LOAD MATERIAL
refers to a large quantity of material that is not
packaged into individual units but is handled in a
loose, unpackaged form. This approach is often
used for materials that are not practical to handle
individually.
Average Bulk Angle of
Material
Density kg/m3 Repose
Alumina 800–1040 22
Cement, Portland 1500 39
Coal, anthracite 960 27
Iron ore 1600–3200 35
Lime, hydrated 560–720 40
Rice Grain 720-768 20
Sand, foundry 1440 39
Slag 1280–1440 25
Wheat 720–768 28
SOLID
composed of molecules or atoms that are tightly
packed together that can maintain a rigid
structure.
Unit Load Bulk Load
Material Material
LIQUID
composed of molecules or atoms that strong
enough to keep them relatively close together
Unit Load Bulk Load
Material, IBC Material
GAS
Gases are composed of molecules or atoms that
are in constant random motion, colliding with each
other and the walls of their container
Unit Load Bulk Load
Material Material
SLURRY
a mixture of solid particles suspended in a liquid,
in which the solid particles are not dissolved in
the liquid.
Unit Load Bulk Load
Material Material
Mechanical Engineering Department
Material Handling Equipment
Engr. Edward Henrick H. Aguda, [Link]., PME
Faculty of Engineering, University of Santo Tomas
CLASSIFICATION OF EQUIPMENTS
Storage Transport Conveyor Hoisting Auxiliary
STORAGE CONTAINER
is any vessel or device used to hold, protect, and
transport materials or products. Its primary function is to
facilitate the safe and efficient handling of goods during
shipping, storage, and distribution
SHOP CONTAINER
Designed to hold a specific quantity or type of goods
(unit load) for efficient handling within a shop,
warehouse, or retail environment. These containers
facilitate the organization, movement, and storage of
products in a unitized form, which simplifies inventory
management and streamlines operations
2000 kg 1000 kg 500 kg
PALLET SKID
It is essentially a platform used for assembling, storing It is essentially a platform provided with legs so that a
and handling of materials as a unit load. Essential platform truck may get inside it and raise it from ground.
feature of a pallet is that the forks of a lift truck can be Skids are thus single-faced and non-stackable.
inserted at the bottom side of the platform, while the
pallet is resting on floor and thus can raise the pallet
with load and move it to desired place
MORE STABLE AND CHEAPER AND CAN BE
CAN BE STACKED DRAGGED
PALLET PATTERN
refers to the specific way items or products are
organized and stacked on a pallet for transportation and
storage. Proper pallet patterns are crucial for maximizing
space, ensuring stability, and preventing damage during
handling and shipping
UNIT LOAD DEVICE
is a device that restrains cargo, mail, perishable goods
and baggage during air transportation. This is either the
solid metal containers you’ve probably seen at an airport
or a pallet with mesh netting that holds the contents in
place
LD3 = 1500 kg LD7 = 5000 kg LD9 = 6000 kg
INTERMODAL CONTAINER
is a large metal crate designed and built for intermodal
freight transport, meaning these containers can be used
across different modes of transport – such as from ships
to trains to trucks
WAREHOUSE
A warehouse is a commercial building or facility used for
the storage of goods, materials, products, and inventory.
It serves as a central location where items are stored
temporarily until they are needed for distribution, sale,
manufacturing, or other purposes.
BULK CONTAINER
Designed To accommodate and manage large quantities
of materials that are stored in bulk rather than as
individual items or packaged units. This type of storage
is designed to handle, store, and sometimes process bulk
quantities efficiently
BIN
A bin is a large container of cylindrical or rectangular
shape made from sheet metal supported on legs. Filling
of bins is from the open or covered top and discharge is
from the bottom opening. Inside agitators or outside
vibrators are used for facilitating flow of materials from
the discharge opening.
BUNKERS
A bunker is essentially a large bin, used for storage of
materials like coal in a power station. These may be a
few hundred meters in length. Belt conveyors, with
automatic trippers, dumpers etc. are used for filling of
the bunkers
SILOS
is a large, vertical storage structure designed for
holding bulk materials such as grains, cement, coal,
or other bulk substances. Silos are commonly used
in agriculture, construction, and industrial
processes to store materials in a controlled and
efficient manner.
Underground Silo Missile Silo
OPEN PILE STORAGE
Some solids, in bulk are frequently stored in open
storage piles. These materials which are not weathered
easily and need to be stored and reclaimed at
substantial hourly rate are kept in open pile storage. The
piles can contain materials from 5000 tons to some
million tons, while handling rate may vary from 100 to
2000 tonnes per hour
ENGINEERING DESIGN
storage tank involves multiple engineering considerations to
ensure the tank can safely and effectively store the intended
materials. The design process typically includes several key
steps, each addressing different aspects of tank functionality
and safety.
Requirements and Specifications
Compliance and Standards
Material Selection
Cost
GLOBAL SUPPLY CHAIN TRANSPORTATION
Road Maritime Air Rail Pipeline
INDUSTRIAL VEHICLES/TRUCKS
These are manual or power driven vehicles suitable for
movement of mixed or unitized load, intermittently,
where primary function is maneuvering or transporting.
The vehicle/truck is physically moved along with the
load from one point to another via a flat or slightly
inclined route. This classification excludes highway
vehicles, railroad cars, marine carriers and aircrafts.
Industrial Vehicles
Non-Powered Trucks Powered Trucks
have no source of motive power, these are generally are vehicles designed for the movement, lifting, and
moved manually or are attached to other powered transportation of heavy materials, goods, and
moving equipment/units products within warehouses, factories, construction
sites, and other industrial settings
TWO-WHEEL HAND TRUCK
These are generally used for moving unit or
unitized loads like bags, barrels, boxes, cartons,
bales, cylinders etc. by pushing the truck manually
MULTIPLE-WHEEL HAND TRUCK
These trucks generally consists of a platform or
framework mounted on 3 or 4 or more number of
wheels. The truck is generally provided with a
handle for pushing or pulling the platform
MULTIPLE-WHEEL HAND TRUCK
These trucks generally consists of a platform or
framework mounted on 3 or 4 or more number of
wheels. The truck is generally provided with a
handle for pushing or pulling the platform
Different Design of Dollies
Maximum load = 700 kg
HAND LIFT TRUCK
These hand trucks are provided with a mechanism
of lifting its platform, which can be rolled under a
pallet or skid, and raised to lift the pallet or skid
with load to clear the ground and then move this
load from one place to another
Maximum load = 700 kg
FORKLIFT
is a specialized vehicle designed for the lifting,
moving, and transportation of heavy materials and
goods
Maximum load = 3000 kg
PLATFORM LIFT TRUCK
is a type of powered industrial vehicle used to
provide temporary access to elevated areas for
maintenance, construction, repair, or other tasks.
TRACTORS
are used in a wide field of activities, starting from
agriculture to earth-moving, municipal waste handling,
construction and industries. A tractor may be fitted with
different attachments to do different jobs like sweeping
sidewalks, plough snow, excavate ground, scoop loading,
bull dozing etc.
TRAILER
Are load bearing wheeled vehicles or cars without any motive power,
designed to be drawn by a tractor or truck. Trailers are classified as
semitrailer and full trailers. A semi trailer is a truck-trailer having one
or more axles and constructed so that a part of its weight is carried by
the truck/tractor. A full trailer is constructed to carry almost all its
weight on its own wheels
ENGINEERING DESIGN
Engineering considerations include ensuring the
forklift's design aligns with load capacity and stability
requirements, selecting appropriate tires and
counterweights, and accommodating the operational
environment, such as surface conditions and space
constraints. Safety features like good visibility, warning
systems, and proper training are essential to prevent
accidents
CONVEYOR SYSTEM
These are gravity or powered equipment commonly used for moving bulk or unit load continuously or
intermittently, uni-directionally from one point to another over fixed path, where the primary function is
conveying of the material by the help of movement of some parts/components of the equipment. The equipment
as a whole does not move.
BELT CONVEYOR
A belt conveyor consists of an endless flat and flexible
belt of sufficient strength, made of fabric, rubber, plastic,
leather or metal, which is laid over two metallic flat
pulleys at two ends, and driven in one direction by
driving one of the two end pulleys. Belt conveyors are
the most common type of conveyor and are generally
employed for continuous flow of material.
CHAIN CONVEYOR
Characterized by one or multiple strands of endless chains that
travel entire conveyor path, driven by one or a set of sprockets at
one end and supported by one or a set of sprockets on the other
end. Materials to be conveyed are carried directly on the links of
the chain or on specially designed elements attached to the chain.
Commonly used for heavy unit loads.
CABLE CONVEYOR
These conveyors form a distinct group of materials handling
equipment to transport people and bulk materials in load
carrying buckets, using overhead moving cables and/or wire
ropes and are composed of one or more spans from the loading
point to the discharge point/points covering long distances up to
several kilometers. Commonly used for loads to be move on high
elevation or uneven terrain.
ROLLER CONVEYOR
A roller conveyor supports unit type of load on a series
of rollers, mounted on bearings, resting at fixed spacings
on two side frames which are fixed to stands or trestles
placed on floor at certain intervals. A roller conveyor
essentially coveys unit loads with at least one rigid, near
flat surface to touch and maintain stable equilibrium on
the rollers, like ingots, plates, rolled stock, pipes, logs,
boxes, crates, moulding boxes etc
SCREW CONVEYOR
A screw conveyor consists of a continuous or interrupted
helical screw fastened to a shaft which is rotated in a U-
shaped trough to push fine grained bulk material
through the trough.
ENGINEERING DESIGN
It's crucial to consider load capacity, conveyor type,
speed, and throughput to match the specific needs of the
application. Ensure material compatibility with the
conveyor’s construction, and evaluate the operating
environment, space constraints, and ease of
maintenance. Safety features must be incorporated to
protect operators, while cost and budget constraints
should be analyzed for both initial and long-term
expenses
HOISTING EQUIPMENT
These equipment are generally utilized to lift and lower
and move unit and varying loads intermittently, between
points within an area known as the reach of the
equipment, where the primary function is transferring. A
hoisting equipment may also be mounted on a powered
vehicle when the movement of the lifted load is not
limited within a fixed area of operation.
HOIST
Hoist is an apparatus for raising or lowering a load
suspended from a hook on the end of a chain or wire
rope. A hoist may be fixed i.e., stationary, base mounted
or supported from overhead by a clevis or hook
WINCHES
is an equipment for pulling a heavy load by winding one
or two ropes on a rope drum. It is a stationary equipment
which is fixed to the floor or wall.
ELEVATORS
is used to signify a group of materials handling
equipment which carries materials up or down. The
group includes a number of diverse type of equipment
like bucket elevators, skip hoists, freight elevators, lifts
etc. Some of these equipment have been discussed in
this section
CRANE
is a materials handling equipment for lifting or lowering
a load by a hook and moving (transferring) it
horizontally, in which the hoisting mechanism is an
integral part of the equipment. A crane may be driven
manually or by power and may be fixed or mobile
Stationary crane Revolving crane Mobile crane
DERRICK
is an apparatus consisting of one or two masts or
fabricated strut members supported at the bottom by a
pivoting arrangement and held at the top by guys or
braces, with or without a boom, for use with a hoisting
mechanism and operating rope, for lifting and lowering a
load and moving it horizontally
ROBOTIC HANDLING
Are specially designed robots tasked of move a part from
one location to another within the workplace or a
slightly more complex operation. Robotic systems can
work around the clock without breaks, further boosting
operational efficiency and throughput
Cylindrical Arm Robot Cartesian coordinate robots Articulated Robots
ENGINEERING DESIGN
Engineering considerations include determining the
maximum load capacity and ensuring the crane can handle
the required weight safely. Evaluate the reach and height
requirements to ensure the crane can access all necessary
areas within the operational space. Consider the type of crane
(e.g., overhead, mobile, tower) based on the specific
application and environment
AUXILIARY EQUIPMENT
A large number of equipment and attachments which
are used to improve the functionally of the primary
material handling equipment. Many of these auxiliary
equipment are of standard design and specifications and
built by specialist manufacturers
GATES
Gates are used in conjunction with various bulk
materials storage hoppers (bins, silos etc.) to close or
open the outlet and adjust discharge of materials in
batches from the hoppers
CHUTES
are inclined connections between two systems of
materials handling equipment or production equipment,
in the form of troughs of definite geometrical cross
section or pipes, which convey unit or bulk load by
gravity.
LEVEL CONTROL
is measurement of level of materials in large hoppers,
bins or silos through bulk solid level measurement
devices. These give measurement of volume of materials
in the hopper