An automated material handling system (AMH) refers to any type of automation that reduces or eliminates the need for human intervention.
Compared with manual handling that requires physical force to move, lift and retrieve items, automated material handling involves using robots and computerised devices to complete the work instead. Some common examples of automated systems include conveyors, carousels and overhead lifting systems.
While there are pros and cons of both manual and automated handling, often automated systems are favoured because they provide an innovative solution versus human labour. In particular, within a manufacturing environment, some tasks may not even be possible without automated machinery meaning businesses can use the technology grow and scale.
Here is an overview of automated material handling systems from the Metreel team to give you further insight.
Why Is Automation Used In Material Handling?
Similar to how processes within manufacturing, warehouses and even in our homes can be automated, there are various benefits to be had by allowing the robots to take control.
Machines can typically work quickly and efficiently, with some tasks far easier and safer to complete with automation versus if a human was to do the same work. A common example is heavy lifting around a warehouse, which could pose a risk to human safety, and may cause disruption while the movement is in place.
However, with automation, heavy loads and any other requirements can be handled with ease. As a result, the business becomes more profitable as tasks can be completed speedily, and the likelihood of employee injury rapidly decreases.
Automated Material Handling System Examples
Automated material handling systems encompass a broad and growing range of technologies, all designed to move, store and manage materials through industrial and warehouse environments with greater speed, safety and efficiency than manual methods alone can achieve.
From the overhead crane systems and powerfeed solutions that Metreel has been supplying to UK industry since 1969, through to warehouse management software and robotic fulfilment technology, the category spans everything from single pieces of handling equipment to fully integrated facility-wide systems.
The following examples give an overview of the main automated material handling systems in use across manufacturing, logistics and distribution operations today.
Automated Guided Vehicles (AGVs)
Floor-level vehicles that follow predefined paths to transport pallets, components or goods between locations within a warehouse or factory without a human operator
Automated Storage And Retrieval Systems (AS/RS)
High-density racking systems with automated cranes or shuttles that store and retrieve pallets or totes at speed, maximising vertical space and reducing manual handling
Barcode And RFID Scanning Systems
Automated identification technology that tracks the movement of goods, components and assets through a facility in real time, feeding data into warehouse management systems
Carousel Systems
Rotating horizontal or vertical storage units that bring goods directly to the operator, reducing travel time and improving pick accuracy in high-SKU environments
Conductor Bar Systems
Electrified rail systems mounted overhead or along the floor that supply continuous power to moving equipment such as cranes and conveyors throughout their full range of travel
Conveyor Systems
Belt, roller or chain conveyors that move products continuously between workstations, picking areas or despatch points without manual intervention
Festoon Cable Systems
Suspended cable management systems that supply power and data to moving machinery along an overhead track, commonly used on cranes, gantries and automated production lines
Gantry Crane Systems
Freestanding overhead crane structures that span a workspace and travel along floor-level rails, used to lift and move heavy loads in areas where a fixed runway is not practical
Monorail And Track Systems
Fixed overhead track systems that carry loads along a predetermined production route, commonly used in automotive, food processing and assembly environments
Overhead Crane Systems
Bridge cranes spanning the full width of a production bay that allow heavy loads to be lifted and traversed to any point within the workspace, forming the backbone of many automated handling operations
Palletising And Depalletising Robots
Robotic systems that automatically stack or unstack palletised goods at the end of a production or despatch line, replacing repetitive and physically demanding manual tasks
Pick-To-Light And Put-To-Light Systems
Light-directed picking technology that guides operators to the correct storage location, increasing speed and accuracy in order fulfilment and kitting operations
Robotic Pick-And-Place Systems
Robotic arms used to pick, sort, pack or position items at high speed with consistent accuracy, widely used in packaging, food production and electronics manufacturing
Sortation Systems
High-speed conveyor-based systems that automatically divert parcels, cartons or totes to the correct outbound lane or despatch point based on barcode or RFID data
Warehouse Management Systems (WMS)
Software platforms that direct and coordinate automated equipment, manage inventory locations and optimise the flow of goods through a facility in real time
Workstation Crane Systems
Lighter-duty crane systems mounted within a defined work cell that assist operators with repetitive lifting tasks on assembly lines, reducing injury risk and improving throughput
Where Are Automated Material Systems Used?
Airport baggage handling – Transporting suitcases through airports involves a secret network of tunnels, scanners and sorters. With Heathrow Airport alone handling 3,000 pieces of luggage per hour, without automated systems, everything would soon grind to a halt.
Manufacturing and bulk handling – The very nature of production lines is that things need to keep moving to hit targets. With so many components to manufacture, an automated process means production can take place over a longer period of time (i.e 24/7 production lines) and be completed quickly. Likewise, with bulk handling, the machinery can move components to wherever they need to be in a much faster timescale versus human labour since it would require a lot of labour to move a heavy object if it would even be possible factoring in current health and safety laws.
Postal and parcel delivery centres – Automated systems can also help sort items at a much faster rate than humans ever could. Considering how much mail moves around not just the UK but the world every day, an automated system is the difference between a letter taking a couple of days to arrive versus weeks.
Warehousing and distribution – Warehouses and distribution centres aren’t only busy spaces, but their contents are usually tightly packed together. With space at a premium and the risk of injury high, automated systems can ensure items are moved between different sections in the safest way possible.
Automated vs Manual Material Handling
Material handling is a fundamental part of almost every industrial operation, but the approach businesses take to managing it varies considerably. At one end of the spectrum sits fully manual handling, where people lift, carry and position loads using their own physical effort. At the other sits full automation, where technology takes on those tasks with little or no human involvement. In practice, most facilities operate somewhere between the two, combining automated systems with manual processes depending on the nature of the work.
Manual material handling relies on workers to move, lift and position goods and materials by hand, sometimes with the assistance of basic aids such as trolleys, pallet trucks or hand trucks. It is flexible, low-cost to implement and well suited to operations dealing with low volumes, highly varied products or tasks that require human judgement and dexterity. However, manual handling carries an inherent risk of injury, particularly where loads are heavy, repetitive or awkward. It is also subject to variability in speed, output and accuracy depending on operator fatigue and availability.
Automated material handling replaces or supplements manual effort with technology-driven systems. It includes the likes of overhead cranes, conveyors, automated guided vehicles, robotic systems and the powerfeed infrastructure that keeps them operational. These systems move and manage materials consistently, at speed and without the physical limitations that affect human workers. The result is higher throughput, reduced injury risk, greater accuracy and a more predictable operational output. The trade-off is a higher upfront investment and the need for ongoing maintenance and technical expertise to keep systems running effectively.
Metreel Handling Equipment Examples
Automated Material Handling System FAQs
Discover more about automated material handling systems below. If you have any further questions for our team or would like to place an order with Metreel, please call us on 0115 932 7010.
What Is Automated Material Handling?
Automated material handling refers to the use of technology-driven systems and equipment to move, store, control and protect materials and products throughout a manufacturing, warehousing or distribution facility with minimal manual intervention. Rather than relying solely on human labour to lift, transport and position loads, automated material handling integrates machinery such as overhead cranes, conveyors, automated guided vehicles and robotic systems to carry out these tasks more consistently, safely and efficiently. At Metreel, our handling systems are designed to form the backbone of automated workflows in industrial environments across the UK.
What Is An Automated Material Handling System?
An automated material handling system is an integrated network of equipment and controls that manages the movement and positioning of materials through a facility without constant manual operation. A typical automated material handling system combines lifting equipment such as overhead or workstation cranes, powerfeed and conductor systems to supply power to moving machinery, and control technology that coordinates each element of the process. The result is a more productive and safer working environment, with reduced reliance on manual handling and greater consistency across operations.
What Are The Different Types Of Automated Material Handling Systems?
Automated material handling systems cover a wide range of technologies depending on the application and industry. Common types include overhead crane systems for lifting and traversing heavy loads across a workspace, monorail and track systems for moving components along a fixed production route, conveyors for continuous transfer of goods, automated guided vehicles for flexible floor-level transport, and robotic pick-and-place systems for high-speed repetitive tasks. Powerfeed solutions such as festoon cable systems, reeling drums and conductor bars are also essential components, providing reliable power and data connections to moving elements within the wider automated system.
What Are The Benefits Of Automated Material Handling Solutions?
Automated material handling solutions deliver a range of operational and safety benefits for industrial businesses. By reducing the need for manual lifting and repetitive physical tasks, they lower the risk of workplace injuries and support compliance with health and safety legislation, including LOLER and PUWER. Productivity increases as movements become faster, more consistent and less dependent on operator availability. Automated material handling solutions also reduce product damage, improve throughput and provide greater traceability across the production or warehousing process. For businesses investing in long-term capacity, they offer a scalable foundation that can be expanded as operational demands grow.
What Automated Material Handling Equipment Does Metreel Supply?
Metreel supplies a comprehensive range of automated material handling equipment designed and manufactured at our facility in Ilkeston, Derbyshire, which is supplied right across the UK.
Our product range includes overhead cranes, workstation cranes, jib cranes, gantry systems and monorails for load movement. We also offer a full suite of powerfeed solutions, including festoon cable systems, steel drag chains, reeling drums and conductor systems that keep automated equipment powered and operational. Every system is built to order and specified to the precise requirements of your facility, duty cycle and load profile.
To discuss your automated material handling requirements, contact our team for a free consultation.
Automated Material Handling Systems UK
There’s a lot to consider when it comes to choosing a handling system for your operation, whether the items are automated or indeed manual. So if you’re in need of further help or advice, you’re in the right place.
Metreel is a leading supplier of warehouse equipment relating to handling, fall protection and power feeds. From cranes to safety harnesses, you’ll find it all here at Metreel. We’re based in Ilkeston, Derbyshire covering the UK and beyond.
If you would like to find out more about our products, or if you’re interested in any other of the services we provide, please give us a call on 0115 932 7010 or drop us an email.
Alternatively, check out the Metreel Brochure to discover our full range of products and services.