Modular Carts for Custom Material Handling Trains

Warehouses and distribution centers need to be flexible in order to be successful. Tugger train systems — also known as custom material handling trains — offer a simple way to add that flexibility.

In a tugger train system, modular carts are connected with a tow bar. The “train" moves through your facility along a predetermined route, delivering products and materials as needed and potentially picking up additional loads along the way. 

Fundamentally, it’s a simple way to get raw materials, finished products, and supplies where they need to be. It’s an excellent and affordable way to build a “milk run" approach to intralogistics; a single set of vehicles performs multiple stops along the route, optimizing the efficiency of each delivery. 

Modular carts can be used to adapt the tugger train for virtually any application, increasing productivity and throughput on day one. Below, we’ll explain how to choose modular carts to support your operation’s processes. 

To discuss custom material carts with a member of our sales team, call (314) 696-0200 or click here to submit a request online.

Modular Carts for Tugger Trains: Benefits and Use Cases

Tugger trains have quickly caught on as an intralogistics solution for several reasons. They’re inexpensive, effective, and versatile — and perhaps more importantly, they’re relatively safe. 

The tugger vehicle follows a standard transport route, and operators typically have excellent control and a better level of visibility (as compared to forklifts and other traditional material handling solutions). 

They’re an especially effective option for line feeding in manufacturing facilities, order fulfillment at distribution centers, and moving pallets around the factory floor. 
Solus Group carries a variety of modular carts, all of which can be customized with different form factors, capacities, and hitches. Options include: 

• Quad Steer Tugger Carts (TT-QS) achieve a predictable follow pattern via a quad-steer mechanism, freeing operators to focus on the travel path. Heavy-duty steel allows for a standard load capacity of 2,000 lbs., and higher capacities are available with custom units. 
• Center Steer Tugger Carts (TT-CS) provide an exceptional level of maneuverability with a fifth caster in the center of the frame. The center wheel is slightly larger than the primary wheels, allowing the unit to pivot in place. A line of Center Steer Tugger Carts can effectively move through narrow aisles with tight turns. 
• Industrial Trailers (IT) are a versatile material handling solution for order picking, line feeding, and putaway tasks. Each of the three slotted metal shelves can hold up to 100 lbs. of materials or products. Front and rear hitches, vertical push/pull bars, and welded fork pockets make the Industrial Trailer an excellent solution for tugger trains.

All options can attach to electric tuggers like the Nu-Star PowerPusher®. They’re also compatible with fully automated solutions such as automated guided vehicles (AGVs) or autonomous mobile robots (AMRs). 

Add Tugger Carts to Create a More Versatile Operation

With some planning, modular carts can be utilized to create a leaner, more capable facility. Industrial Trailers can carry inventory directly to workers, simplifying order picking — and on the same train, Quad Steer Tugger Carts can carry pallets or other heavier items to where they’re needed. 

At Solus Group, we’re dedicated to helping your facility find safe, ergonomic ways to improve productivity. Whether you need custom modular carts built to a certain size specification or specialized heavy-duty trailers that can attach to your current tugger vehicles, we’re ready to provide solutions.

To get started, call 314-696-0200 today to speak with a member of our sales team.