Buyer’s Guide: Choosing Material Handling Equipment for Medium-Sized DCs

Scope: This guide helps procurement and operations teams select the right mix of material handling equipment (MHE) for medium-sized distribution centers (50k–250k sq ft). We cover forklifts, pallet jacks, conveyors, sorters, lifts, and picking aids, plus sourcing tips and total cost considerations.

Step 1 — Define throughput and duty cycle

Start by quantifying throughput: pallets per hour inbound/outbound, peak vs. off-peak demands, and SKU mix. Define duty cycles for each equipment type — how many hours per shift and expected lifespan. This will inform whether to prioritize heavy-duty electric forklifts or lighter walkie pallet jacks.

Forklifts: electric vs. IC (internal combustion)

Electric forklifts have lower operating noise, no onsite emissions, and simpler maintenance. They are ideal for indoor facilities and are increasingly preferred. IC trucks retain advantages for heavy loads and outdoor docks. For medium DCs, a mixed fleet often optimizes cost and flexibility: electric for indoor pallet handling and IC for yard operations and heavy-duty lifts.

Pallet jacks and order pickers

Choose electric pallet jacks for high-volume picking to reduce operator fatigue. Manual jacks remain useful for low-intensity or backup operations. For multi-level picking, order pickers (sit/stand) can improve speed and safety compared to manual ladders.

Conveyors and sortation

Conveyors pay off when there are repetitive moves across fixed routes, such as putaway lanes and packaging lines. Sortation systems (tilt-tray, cross-belt) are efficient for high SKU variety with high throughput. Consider modular conveyors with VFDs so you can extend or reconfigure as volume patterns change.

Picking aids and ergonomic solutions

Install picking workstations with lift tables, anti-fatigue mats, and ergonomic handles. Voice and light-directed picking can reduce errors and improve LPH. For heavier items, invest in lifting aids or vacuum lifters to reduce injury risk.

Vendor selection and procurement tips

• Buy from vendors that offer robust after-sales support in your region.
• Evaluate total lifecycle cost: maintenance, consumables (batteries), and parts availability.
• Consider leasing or pay-per-use options for high-capex items if cash flow is a constraint.
• Standardize on a small number of suppliers to reduce spare parts complexity.

Safety and compliance

Ensure all equipment meets local OSHA/health and safety regulations. Train operators and maintain a documented inspection schedule. Keep a stock of critical spare parts to reduce MTTR and avoid production bottlenecks.

Sizing and scalability

Design equipment capacity for peak loads plus a margin. For conveyors and sorters, choose modular systems that can be extended with minimal disruption. For fleets, plan for telematics to monitor utilization and schedule preventive maintenance.

Case example

A 100k sq ft DC optimized its fleet: replaced most internal combustion forklifts with electric counterbalance for indoor zones and added 10 electric pallet jacks to high-velocity zones. The result: 15% lower fuel/energy cost (accounting for charging), 12% reduction in maintenance incidents, and improved indoor worker comfort.

Checklist before purchase

1. Confirm throughput and duty cycles for each equipment class.
2. Get references and visit live sites where the equipment is deployed.
3. Ask vendors for TCO models and spare parts lead times.
4. Plan for operator training and a spare parts kit for each machine type.
5. Negotiate SLAs for repairs and expected MTTR guarantees.

Conclusion

Procurement decisions should balance upfront cost, lifecycle cost, and operational flexibility. Prioritize equipment that improves uptime, reduces variable labor, and integrates with your broader material flow strategy. When in doubt, pilot equipment under realistic shifts before committing to full-scale purchase.