BATANGAS STATE UNIVERSITY

College of Engineering, Architecture, Fine Arts

Gov. Pablo Borbon Campus II, Alangilan, Batangas City, Philippines 4200
www.batstate-u.edu.ph Telefax: (043) 300-4404 locs. 106-118

CHEMICAL AND FOOD ENGINEERING DEPARTMENT

MATERIAL HANDLING

Submitted by:
John Bryan Aldovino
Francesca Hainah M. Feranil
Pauline Lopez

Submitted to:
Engr. Rodolfo Sotto Jr.
MATERIAL HANDLING is the movement, storage, control and protection of materials, goods
and products throughout the process of manufacturing, distribution, consumption and
disposal. The focus is on the methods, mechanical equipment, systems and related controls used
to achieve these functions. Material Handling is the art and science of moving, storing, protecting,
and controlling material. Material handling is a necessary and significant component of any
productive activity. It is something that goes on in every plant all the time. Material handling
means providing the right amount of the right material, in the right condition, at the right place, at
the right time, in the right position and for the right cost, by using the right method.
Material Handling means providing:
– the right amount
– the right material, at the right time
– in the right condition
– at the right place
– in the right position
– in the right sequence
– for the right cost
– using the right method(s).

OBJECTIVES OF MATERIAL HANDLING

1. Increase the efficiency of material flow

2. Reduce MH cost
3. Improve facilities utilization
4. Safety and working conditions
5. Manufacturing process
6. Increase productivity

MATERIALS HANDLING PRINCIPLES:

1. Standardization
2. Work (cost x flow)
3. Ergonomic
4. Unit Load
5. Space Utilization (3-D)
6. System
7. Automation
8. Environmental
9. Life Cycle Cost
10. procurement-removal

MATERIALS HANDLING SYSTEM DESIGNS:

1. Define the objectives & scope

2. Analyze the requirements
3. Generate alternative designs
4. Evaluate alternative designs
5. Select the preferred design
6. Implement the preferred design

SELECTION OF MATERIAL HANDLING EQUIPMENT

1. Properties of the Material- Whether the material is solid, liquid or gas, and in what size,
shape and weight it is to be moved, are important decisions and can be lead to a preliminary
elimination from the range of available equipment under review.
 2. Layout and Characteristic of the building- availability of space for handling

- Low-level ceiling many preclude the use of hoist or cranes, and the presence of supporting
columns in awkward places can limit the size of material handling equipment

3. Production Flow- If the flow is fairly constant between two fixed position that are not
likely to be changed, fixed equipments such as conveyors or chutes can be successfully
used.

- If, on the other hand, the flow is not constant and the direction changes occasionally from
one point to another because several products are being produced simultaneously, moving
equipments such as trucks would be preferable.

4. Cost Considerations- This is the most important consideration.

- Several cost elements need to be taken into consideration when comparisons are made
between various items of equipment that are all capable of handling the same load.

- Initial investment and operating and maintenance cost are the major costs to be considered.

5. Nature of Operations- Selection of equipment also depends on the nature of operations

like whether handling is temporary or permanent, whether the flow is continuous or
intermittent and material, flow pattern-horizontal or vertical.
6. Engineering Factors- Engineering factors such as door, ceiling dimensions, floor space,
floor conditions and structural strengths are also taken in consideration in the selection of
equipment.
7. Equipment reliability- Reliability of the equipment and supplier reputation and the after
sale services plays an important role in selecting the equipment.

REDUCING COST HANDLING

The total cost of material handling per unit must decrease. The total cost per unit is the sum of the
following:

1. Cost of material handling equipment – both fixed cost and operating cost calculated as the
cost of equipment divided by the number of units of material handled over the working life
of the equipment.
2. Cost of labor – both direct and indirect associated cost calculated in terms of cost per unit
of material handled.
3. Cost of maintenance of equipment, damages, lost orders and expediting expenses, also
calculated, in terms of cost per unit of material handled.

UNIT LOADS

A unit load is the unit to be moved or handled at one time. A unit load includes the container,
carrier, or support that will be used to move materials.
 • Examples: tote boxes, “cassette”, cartons, skids, pallets, pallet boxes, intermodal container,
one unit of product, etc. Most popular: plastic containers and pallets

Factors for determining unit load/ container:

– Size of carrier
– Size and weight of items
– Space for storing loaded/unloaded container
– Equipment used for moving
– Cost, supply and maintenance
– Aisle widths, door sizes, and clear stacking heights
– Environmental regulations

UNIT LOAD AND HANDLING SYSTEMS

The unit load is an integral part of the material handling system and a “simultaneous”
determination should be made.

Unit Load Disadvantages

1. Time spent forming and breaking down the unit load.
2. Empty containers/pallets may need to be returned to their point of origin.
3. Cost of containers/pallets and other load restraining materials used in the unit load
EQUIPMENT UTILISATION RATIO

Equipment utilisation ratio is an important indicator for judging the materials handling
system. This ratio can be computed and compared with similar firms or in the same over a period
of time.

In order to know the total effort needed for moving materials, it may be necessary to
compute Materials Handling Labour (MHL) ratio.

This ratio is calculated as under:

MHL = Personnel assigned to materials handling

________________________________________________________
Total operating work force

In order to ascertain whether is the handling system delivers materials work centres with maximum
efficiency, it is desirable to compute direct labour handling loss ratio.
The ratio is:

DLHL = Materials handling time loss of labor

____________________________________________________
Total direct labor time

STORAGE AND HANDLING EQUIPMENTS

I. Bulk material handling
II. Engineered systems
III. Industrial trucks
IV. Storage and handling equipment

I. BULK HANDLING MATERIAL EQUIPMENT

The term ‘bulk handling equipment’ refers to the storage, control and transportation of
materials by bulk, and in loose form. There are plenty of examples of this application – the
handling of food, beverages, liquids, metal items (such as screws and nails) and minerals are just
a few.

Types of bulk handling material equipment

1. Bucket and grain elevators
2. Conveyor belts
3. Hoppers and silos
4. Reclaimers
5. Stackers

II. ENGINEERED SYSTEMS

An engineered system is one that is typically automated. Such systems are also usually created
from a variety of units. When combined, they work to enable both storage and transportation.

Types of engineered systemsAutomated guided vehicles (AGVs)

1. Conveyor systems
2. Robotic delivery systems

III. INDUSTRIAL TRUCKS

This term is another broad definition that can be applied to many different types of equipment.
Such pieces of equipment do have one thing in common, though – they all provide transportation.

The scope of this term can include both small, hand-operated devices, and large-scale
motorized vehicles. Some items can be driven, while others – such as pallet trucks – simply add
mobility to the materials that are being handled.

Types of industrial trucks

1. Automated guided vehicles (AGVs)
2. Hand, platform and pallet trucks
3. Order pickers
4. Pallet jacks
5. Side-loaders
6. Walking stackers

IV. STORAGE AND HANDLING EQUIPMENT

Equipment that is used for storage usually only encompasses items that are not automated.
Storage equipment is equipment that is used to hold products and materials when they are not
being used, or when they are waiting to enter or leave the production process. These periods
could be long-term, or short-term in order to allow a suitable build-up of stock or finished
items.

Types of storage and handling equipment

1. Drive-through or drive-in racks
2. Pallet racks
3. Push-back racks
4. Shelving
5. Sliding racks
6. Stacking frames