How to Choose the Best Material Handling Solutions for Your Facility

Running an efficient warehouse, manufacturing plant, or distribution center starts with choosing the right material handling solutions. From pallet rack systems to mezzanines, the right equipment layout not only maximizes space but also improves safety, productivity, and employee morale.

Since 1957, Cranston Material Handling Equipment has been helping businesses across Western Pennsylvania, Northern West Virginia, and nationwide design and install systems that work. Here’s how to approach selecting the right equipment for your operation.

1. Start with a Facility Assessment

Before you start shopping for equipment, take a step back and evaluate your space.
Our team at Cranston offers on-site consultations to review:

• Current workflow and bottlenecks
• Available square footage and ceiling height
• Types of products handled and their dimensions
• Safety compliance needs (OSHA and internal standards)
• Budget and timeline for upgrades

By understanding your current challenges and long-term goals, we can recommend solutions that address today’s needs while leaving room for future growth.

Related: Learn more about our custom design services and how we tailor solutions to your exact requirements.

2. Select the Right Pallet Rack System

For most warehouses, pallet racking is the backbone of storage. The right system can drastically increase usable space while making products easier to access.

Common Options:

• Selective Racking: Best for facilities that need direct access to every pallet.
• Drive-In/Drive-Through Racking: High-density storage for bulk items with fewer SKUs.
• Push-Back Racking: Ideal for LIFO (Last In, First Out) inventory rotation.
• Cantilever Racking: Perfect for storing long or bulky items like pipes or lumber.

At Cranston, we offer complete Pallet Rack Systems including installation, safety accessories, and pallet rack inspections to keep your system secure and compliant.

3. Maximize Space with Warehouse Mezzanines

If you’re out of floor space but have unused vertical height, a warehouse mezzanine system is one of the most cost-effective upgrades you can make.

Benefits:

• Doubles or triples usable space without expanding the building footprint
• Creates room for offices, additional storage, or production areas
• Modular designs that can be reconfigured as your needs change

Our Warehouse Mezzanine Systems are engineered for safety and efficiency, with options for custom railings, stairs, and load capacities.

4. Improve Workflow with Conveyors and Lifting Devices

Once your storage is set, think about how products move through your facility.

• Conveyors can reduce walking time and improve throughput. See our Conveyor Solutions for flexible layouts and equipment types.
• Cranes and Lifting Devices make handling heavy materials safer and faster. Learn more about our Cranes and Lifting Devices options, including jib cranes and gantry cranes.
• Industrial Lift Tables and Pallet Positioners improve ergonomics and reduce strain on workers.

These systems integrate seamlessly with your racking and storage to create a smooth, efficient workflow.

5. Prioritize Safety from the Start

Safety isn’t an afterthought — it’s a core part of every material handling plan. Cranston offers:

• Pallet Rack Inspections to spot structural damage before it leads to accidents (learn more).
• Wire Mesh Partitions & Fencing to secure inventory or protect high-traffic areas (partitions & fencing solutions).
• Safety Equipment such as guardrails, bollards, and dock safety products (safety equipment page).

By integrating these systems early, you avoid costly retrofits and maintain compliance with industry regulations.

6. Consider Specialized Storage for Small Parts

Not all inventory is palletized. Many facilities require specialized systems for small parts, tools, and components.

While Cranston provides modular drawers, shelving, and cabinets for these needs, some operations may benefit from high-density vertical storage. These solutions are especially useful in facilities with limited floor space or a high mix of SKUs.

 

By combining Cranston’s traditional storage systems with selective high-density options, you can cover every storage scenario.

7. Industry-Specific Considerations

Every industry has unique material handling challenges:

• Manufacturing: Heavy-duty pallet racks, mezzanines for assembly areas, and lift tables for ergonomics.
• Distribution: High-density racking, conveyors for order fulfillment, and robust safety equipment for busy loading docks.
• Retail Backrooms: Modular shelving, pallet racks, and secure partitions for inventory control.
• Cold Storage: Racking and mezzanines built from corrosion-resistant materials.

Our experience across these sectors ensures your solution meets both operational and regulatory requirements.

8. Mistakes to Avoid When Choosing Material Handling Solutions

• Using the wrong rack type for your inventory: Mismatched systems can reduce efficiency and cause safety hazards.
• Ignoring weight and seismic ratings: Overloaded or non-rated equipment risks failure.
• Skipping professional installation: Improper assembly can void warranties and lead to accidents.
• Neglecting regular inspections: Even the best equipment requires ongoing maintenance.

Working with a partner like Cranston helps you avoid these pitfalls and keeps your facility running smoothly.

9. Plan for Future Growth

Your material handling needs will evolve as your business grows. The best systems are scalable, modular, and adaptable.

Tips for Long-Term Planning:

• Choose racking and mezzanines that can be expanded or reconfigured.
• Select conveyor layouts that allow for future upgrades, or explore warehouse automation solutions that can be integrated later as your operational needs evolve.
• Work with a partner who can revisit your facility as needs change — Cranston has been that partner for clients for over 65 years.

Why Work with Cranston Material Handling

When you choose Cranston, you’re getting:

• Decades of experience across industries
• Access to products from over 200 manufacturers
• Professional installation, including wiring, HVAC, and floor coverings
• Full project management so you can stay focused on your business

Our goal is simple: help you create a safer, more efficient, and more productive workspace.

Take the Next Step

Whether you need a complete warehouse redesign or a single piece of equipment, Cranston is here to help.

📞 Contact us today for a free proposal and on-site consultation.

Frequently Asked Questions (FAQs)

1. What are material handling solutions?
   Material handling solutions refer to the equipment, systems, and processes used to move, store, control, and protect materials in a facility. This includes pallet rack systems, mezzanines, conveyors, cranes, and safety equipment. At Cranston Material Handling, we provide customized designs and professional installation to ensure your system meets your specific operational needs.

 

2. How do I know which pallet rack system is right for my facility?
   The best pallet rack system depends on your inventory type, storage density needs, and picking process. For example, selective racks are great for direct access to each pallet, while drive-in racks work well for bulk storage. Learn more on our Pallet Rack Systems page or schedule a consultation for a personalized recommendation.

 

3. What are the benefits of a warehouse mezzanine?
   Warehouse mezzanines allow you to add usable square footage without expanding your building. They’re perfect for creating office space, storage areas, or production platforms. See our Warehouse Mezzanine Systems for design options and load capacities.

 

4. How often should I schedule a pallet rack inspection?
   We recommend a pallet rack inspection at least once a year, or more frequently if your facility experiences heavy usage or high forklift traffic. This helps identify damage to anchors, uprights, beams, and safety clips before it becomes a safety hazard. Learn more about our Pallet Rack Inspection service.