Material Handling Equipment: NIOSH’s 4 Most Useful Solutions

Whether you’re running a warehouse, manufacturing facility, or any other type of industrial operation, material handling equipment (MHE) plays a critical role in your business’s success. 

Overexertion is the leading cause of disabling injuries according to the 2022 Liberty Mutual Workplace Safety Index, responsible for $12.63 billion in direct costs; “other exertions" caused by awkward postures costs employers an additional $4.01 billion in direct costs. (If you’re interested in more specific numbers, OSHA also provides a calculator to estimate the direct costs of occupational injuries on company profitability). 

The indirect costs of poor ergonomics are substantially higher; higher turnover rates and lower throughput can quickly outweigh the costs of task-appropriate equipment. 

Of course, that prompts a question: What types of tools are most effective for limiting overexertion and improving productivity?

The Four Most Useful Material Handling Solutions, Per NIOSH

While the answer largely depends on the task at hand, some types of MHE are more generally useful. In 1981, the National Institute for Occupational Safety and Health (NIOSH) published Work Practices Guide for Manual Lifting, a groundbreaking report that outlined the most useful MHE for industrial businesses.

For factories, NIOSH identifies four material handling systems as especially helpful in limiting the need for manual lifting:

1. Conveyors
2. Cranes and hoists
3. Positioning equipment
4. Industrial vehicles 

These systems can make manual material lifting less common — and dramatically limit on-the-job injuries. Here’s where they make the most sense.

1. Conveyors 

“Conveyors” refers to any system that moves loads vertically or horizontally in a continuous manner. That can include roller conveyors, belt conveyors, screw conveyors, monorails, and trolley conveyors. 

More generally, the term extends to vertical reciprocating conveyors (VRCs) and freight elevators. (Learn about the key differences between freight elevators and VRCs). According to the NIOSH guide, conveyors are most useful when tasks meet these criteria:

• Loads are uniform;
• Materials move continuously;
• Routes do not vary;
• Loads are constant;
• Movement rate is relatively fixed;
• Conveyors bypass cross traffic;
• The path is fixed; and
• Movement is from one point to another.

It’s important to feed conveyors with appropriate material handling equipment. After all, if workers must lift heavy loads to dump products onto a conveyor belt, that’s a problem — even if the conveyor is handling most of the work from that point forward.

Products to Consider

Vertical Reciprocating Conveyor (VRC)
Ideal for multi-level facilities across various industries, BHS VRCs efficiently move pallet loads, loose materials, and heavy equipment between floors. Conformant with ASME standards, they offer seamless integration with your existing conveyors and material handling systems. 

Push-button controls, rapid lift times, and safety features like velocity fuses, drop locks, and gate sensors prioritize both efficiency and safety.

Bin Dumpers
Bin Dumpers lift and tip drums, storage bins, and other high-capacity containers, eliminating the need for manual lifting. They’re an excellent option for feeding conveyor lines in manufacturing facilities, shipping centers, and other operations. Cost-effective, lightweight, and maneuverable, Bin Dumpers can be installed in static locations or moved along the conveyor line. 

2. Cranes and Hoists

As their names imply, cranes and hoists are overhead systems that lift and lower objects. They are most useful when:

• Loads are heavy or bulky;
• Lifting and lowering is required frequently;
• Loads are non-uniform;
• Movement is within a fixed area; and
• Precise placement is needed.

OSHA has specific standards for cranes, derricks, and hoists, which need to be considered when implementing the equipment. Operators must be trained and certified, and engineering controls should be implemented to minimize fall risks. 

Overhead lifting systems fall into several general categories, each of which has specific advantages:

• Jib Cranes: These cranes have a horizontal boom (or jib) attached to a vertical mast or support structure. They’re ideal for moving automotive and industrial equipment.
• Bridge Cranes: These cranes consist of a hoist trolley that moves along a bridge beam supported by runways on either side. Bridge cranes offer excellent coverage over a large rectangular area, but they’re fairly expensive.
• Gantry Cranes: Similar to bridge cranes, gantry cranes have a hoist trolley that moves along a bridge beam. However, instead of being supported by runways, the bridge is supported by legs (gantries) allowing for movement over open spaces or uneven terrain. Gantries are commonly found in forklift battery rooms, but they’re extraordinarily versatile — and generally inexpensive.
• Chain Hoists: Chain hoists use a chain to lift and lower loads. They are compact and portable, so they work well where space is limited or frequent relocation is needed.
• Wire Rope Hoists: Hoists use a wire rope to lift and lower loads. They offer higher lifting capacities than chain hoists and are suitable for heavier loads.

Products to Consider

Gantry Cranes 
BHS Portable Gantry Cranes are available with or without power drive. Optimized for vertical extraction of lift truck batteries, Gantries also work well in automotive spaces, factories, distribution centers, and in a wide variety of other applications. 

As with all BHS equipment, Gantry Cranes can be customized to meet your facility’s needs. 

Forklift Jib Booms 

BHS Jib Booms are all-steel lifting cranes that can be easily transported via secure fork pockets. They’re available in powered and manual models with capacities of up to 6,000 pounds. Like Gantry Cranes, BHS Jib Booms are made with pure welded steel with a durable powder-coat finish. 

Hoist Kits 

BHS Hoist Kits include manual & motorized trolley options, along with powerful electric hoists that can safely handle up to 3 tons. Hoist kits feature magnetic disc brakes and adjustable upper- and lower-limit switches to regulate load travel. 

3. Positioning Equipment

As the name implies, “positioning equipment” refers to tools and machinery designed to manipulate the position of a load, making it easier to reach or move. This can include lift tables, tilt tables, turntables, pallet positioners, and other similar devices.

Positioning equipment is most useful when:

• Loads need to be raised, lowered, or tilted for access;
• Precise positioning is required for assembly or other tasks;
• Work is performed at varying heights; and
• Frequent adjustments are necessary.

The value of positioning equipment is obvious — but often overlooked. Your workforce is made up of employees with a diverse range of shapes, sizes, and capabilities. By bringing loads to a comfortable working height and orientation for each individual worker, positioning equipment minimizes the need for bending, reaching, and twisting.

That reduces the risk of strain and injury. It’s particularly beneficial in manufacturing, assembly, and packaging operations where workers frequently handle objects at different heights and angles.

Products to Consider

Lift Tables and Pallet Positioners

BHS offers a comprehensive selection of stationary Scissor Lift Tables and Mobile Lift Tables, including units with self-leveling features. Engineered for maximum longevity and performance, BHS Lift Tables are the standard for product assembly, order picking, and other essential tasks. 

Tilt Tables

Tilt Tables don’t just lift loads; they’re also capable of tilting objects up to 90 degrees (or more, in certain applications). 

BHS offers both stationary and mobile Tilt Tables, with capacities ranging from 500 to 5,000 pounds. By quickly adjusting the angle of the load, Tilt Tables eliminate fatigue and strain caused by awkward movements.

4. Industrial Vehicles

Industrial vehicles encompass a wide range of powered vehicles used for transporting materials within a facility or worksite. This includes forklifts, pallet jacks, walkie stackers, order pickers, and other specialized vehicles.

Industrial vehicles are most useful when:

• Loads are heavy and need to be moved over long distances;
• Frequent movement of materials is required;
• Loads are palletized or otherwise easily handled by the vehicle; and
• Efficient material flow is essential.

Industrial vehicles are commonly used in warehouses, distribution centers, manufacturing plants, and construction sites. However, like cranes and hoists, industrial vehicles require proper training and certification to operate safely. Engineering controls (such as established, well-marked travel paths) are essential. 

Products to Consider

Aerial Work Platform (AWP)

Aerial Work Platforms are scissor lifts designed for the safe elevation of personnel. Engineered for seamless integration into your current workflow, they’re compliant with ANSI MH29.1 (Safety Requirements for Industrial Scissor Lifts) and a safer alternative to scaffolding.

BHS AWPs are outfitted with numerous safety features, simple push-button controls, and hardened chrome piston rods for reliable hydraulic performance. 

Forklift Work Platform (FWP)

The BHS Forklift Work Platform (FWP) securely elevates workers for overhead tasks, transforming a forklift into a safe work platform. It boasts safety features like a 42" guard railing, toe guard, an 84” high mast guard, and multiple harness attachment points. The all-steel attachment meets or exceeds federal standards. 

Order Picking Platforms (OPP)

Order Picking Platforms (OPP) convert forklifts into safe, OSHA-compliant elevated platforms for order picking and similar tasks. The OPP features an anti-skid surface, toe guards, and tall steel barriers for safety. Optional casters allow for easy maneuvering.

For an Efficient Operation, Match Your Material Handling Equipment to the Task

The right material handling equipment can make a significant difference in your operation's productivity, efficiency, and safety. By analyzing your needs and matching them to the appropriate solutions, you can streamline your operations, reduce the risk of injuries, and improve your bottom line. 

Whether you’re designing a production process or addressing a specific problem with your current workflow, our experts can help you find a solution that makes sense. Contact us today at 1.800.247.9500 to speak with a member of our sales team or to find a local dealer.