Types of Automated Material Handling Systems Every Factory Should Know

In the rapidly evolving landscape of manufacturing, warehousing, and logistics, automated material handling systems have transitioned from being a luxury to a necessity. As the industry moves towards smart, flexible, and resilient operations, the demand for affordable, reliable, scalable, and easy to deploy automated solutions is reaching an all-time high. 

However, there is a significant gap in decision-makers’ knowledge when it comes to exploring the available next-generation automated material handling systems or understanding which automation equipment is suitable for specific business requirements.

This blog post will provide a comprehensive overview of different types of material handling systems every factory should know, with a special focus on the products offered by Hachidori Robotics, India’s first and largest automation solutions provider. 

By the end of this read, you will be familiar with major automated material movement systems and the factors to consider when choosing the right solution for your factory.

Why Material Handling Automation? 

Material handling involves the movement, storage, protection, and control of goods throughout manufacturing and distribution. Automating these processes can reduce manual labor, errors, improve safety, and provide measurable ROI in the form of increased throughput and operational cost savings. Factories and warehouses that incorporate automation enjoy: 

• Faster, more predictable material flow 

• Enhanced worker safety and reduced workplace injuries 

• Real-time tracking and analytics 

• Scalability and flexibility to adapt to changing business needs

Major Types of Automated Material Handling Systems 

1. Automated Guided Vehicles (AGV) Systems 

AGVs are driverless, self-guided vehicles that move materials within a facility along predefined paths. They are well-suited for transporting pallets, raw materials, and finished goods between workstations, storage racks, and shipping docks.

Features: 

• AGVs follow pre-programmed routes using magnetic tape, QR codes, or laser guidance.

• Available in multiple payload capacities (up to 2 tons in Hachidori’s product range).

• Equipped with safety features such as emergency stop buttons and obstacle detection systems.

Use Cases: 

• Automotive manufacturing 

• FMCG distribution centers 

• Electronics assembly lines 

2. Autonomous Mobile Robots (AMR) for Warehouses 

AMR robots for warehouses are the next-gen evolution of material handling. Unlike AGVs that follow fixed paths, AMRs use a combination of sensors, cameras, and patented indoor GPS navigation to move freely around the warehouse, adapting to dynamic environments.

What sets Hachidori Robotics’ AMRs apart? 

• Proprietary indoor GPS navigation: Accuracy within ±10mm in industrial settings

• Wireless natural navigation technology 

• Real-time material movement tracking, analytics dashboards, and fleet management features

• Customizable for different payloads, facility layouts, and use cases

Benefits: 

• No infrastructure, cables, or floor markings required for navigation

• Easy to deploy and quickly reconfigure for changing needs

• Integration with other robots and systems 

Use Cases: 

• Warehousing and logistics 

• Pharmaceutical distribution 

• Heavy engineering and F&B industries 

3. Conveyor Automation Systems 

Conveyor automation systems automate the movement of goods between production lines, storage, and shipping areas. Conveyor automation systems are ideal for continuous, high-volume material movement to avoid manual handling and bottlenecks.

Dock & Conveyor AMR from Hachidori acts as a critical link between automated storage and retrieval systems (ASRS) and other zones in the factory, ensuring smooth infeed and outfeed operations.

Benefits: 

• Consistent, high-speed material flow 

• Reduction in labor costs and human errors 

• Seamless integration with ASRS and other automation equipment

Use Cases: 

• Electronics manufacturing 

• FMCG packaging 

• Pharmaceutical production 

4. Automated Storage and Retrieval Systems (ASRS) 

ASRS automates the storage and retrieval of goods in warehouses. It uses robotic systems to place and pick items from racks. Combining ASRS with AMRs and conveyors can help achieve optimal space utilization and inventory accuracy.

Bin ASRS and lifting solution AMRs from Hachidori Robotics are designed to work for heavy and small payloads efficiently in high-density warehouses with ultra-fast order fulfillment.

Benefits: 

• Optimized warehouse space 

• Faster order processing and real-time inventory management 

Use Cases: 

• E-commerce fulfillment centers 

• Pharmaceutical warehouses 

• Automotive parts distribution 

5. Tugger and Towing AMRs 

Tugger AMRs are specialized mobile robots designed to tow trolleys, racks, or sub-assemblies within factories. Hachidori’s Tugger AMR features include an auto-attachment system, push/pull capability in both directions, and in-place rotation capability.

Key Metrics: 

• Positioning Accuracy: <3cm 

• Battery: 48V 27AH lithium-ion battery 

• Slope: Can climb a slope of up to 8° when the payload ≤500 kg

Benefits: 

• Efficient transportation of bulky or high-volume materials 

• Minimal manual intervention required 

• Customizable for different factory layouts 

Use Cases: 

• Automotive assembly 

• Heavy engineering 

• F&B logistics 

Addressing the Main Pain Points 

Factories owners and warehouse managers looking to automate operations often face challenges in:

• Uncertainty about which types of warehouse automation systems are available in the market

• Confusion about which factory automation solutions would work best for their use case

• Doubts around navigation, integration, scalability, and ROI 

Hachidori Robotics is committed to alleviating these pain points by providing:

• Customized solutions that address specific industry vertical needs

• A patented, indoor GPS navigation for consistent, infrastructure-free material movement

• Real-time analytics and robust safety features for complete transparency into operations

• Consultation services and live demos to help educate decision-makers

Why Hachidori Robotics? 

Hachidori Robotics is a world-class automated material handling system manufacturer and provider of end-to-end automation solutions for industries across automotive, FMCG, manufacturing, warehousing, electronics, and more. Major unique value propositions include: 

• 100% Made in India AMRs with three patents for indoor positioning and navigation

• Versatile product portfolio: Lifting, towing, docking, conveyor, and ASRS solutions

• Customization: Tailored solutions for specific payloads, layouts, and workflows

• Geographical presence: Offices in major Indian states with a rapidly expanding footprint

• Financial backing: Recently secured $3 million USD in funding

Performance Metrics: 

• Payload: Up to 2 tons 

• Positioning Accuracy: <3cm, with the patented indoor GPS navigation

• Fleet Management: Real-time tracking and analytics dashboards for AMRs

• Safety Features: 2D Lidar, emergency stop button, bumper protection, etc.

How to Choose the Right Material Handling Automation Solution

There is no one-size-fits-all solution for material handling automation. Factors that one must take into account when choosing the right automated material movement system include:

• Type of goods/materials handled (weight, volume, fragility, etc.)

• Facility layout (fixed paths vs. dynamic navigation needs)

• Integration with existing systems 

• Scalability and future expansion plans 

• Expected ROI, in the form of cost savings, efficiency improvements, and safety

Hachidori Robotics has an extensive consultative process to ensure you receive the solution that best fits your operational requirements, unique business goals, and budget.

The Next Steps to Take 

Don’t let your business be stuck in the past. The future of material movement is automated, efficient, and reliable. If you are looking for turnkey warehouse automation solutions, Hachidori Robotics has the knowledge and technology to help you get there.

Contact Hachidori Robotics today to get a custom automation assessment done or to book a live demo. Learn how our patented solutions can transform the way your business handles material movement, increase productivity, and future-proof your operations.