Warehouse Picking Carts: What Logistics Professionals Need to Know

Warehouse picking carts are essential to any order fulfillment operation in modern distribution centers. They allow pickers to fill many orders per trip, unlocking an efficient picking methodology like batch picking or zone picking. Even better, they can contribute to a safer warehouse operation overall. Carrying heavy loads and repeated bending and reaching raise the risk of musculoskeletal disorders, the world’s leading cause of disability. Industrial order picking carts reduce the hazard by bearing loads and positioning shelves at accessible heights, helping to reduce worker fatigue (and therefore labor costs). But not all picking carts for warehouse use are equally ergonomic. In fact, relying on poorly supported manual processes, or using substandard equipment, can reduce warehouse efficiency and increase the risk of injury, as workers must exert more force to operate a faulty cart.

Make no mistake: The order picking process is not risk free. “The disadvantages of [the traditional order pick system] are that Selectors are exposed to a number of musculoskeletal stresses including heavy lifting, bending, reaching, twisting, etc.,” warns the Occupational Safety and Health Administration (OSHA). The solution for warehouses and manufacturing facilities is to provide material handling equipment that reduces these risk factors. Most importantly, warehouse picking carts are designed to fit the work to the worker, streamlining everyday inventory movement in the process. When choosing a fleet of mobile picking carts for your picking operations, here are the features to look for.

• Casters: Material, arrangement, durability. A set of heavy duty caster wheels can make the difference between a helpful cart and efficiency-killing frustration. Warehouse cart caster wheels should be tough, dependable, and smooth-rolling for high-volume internal transport. Look for a combination of two swiveling and two fixed caster wheels; that makes a maneuverable cart that turns on a dime and rolls straight, ideal for narrow aisle racking layouts. Phenolic casters are best for most applications, and high-quality foot brakes help to keep carts secure when stationary.
• Shelves: Number, height, edges. Depending on what your warehouse stocks, or whether you use warehouse bins or cartons, you may need different arrangements of shelving. Some facilities benefit from standard flat shelves, while others require tilted pick shelves for easier access to contents. Note shelf clearance (vertical clearance between shelves) to ensure items or boxes will fit.
• Construction: Frame, finish, capacity. In order to function perfectly after years of hard use, warehouse carts need to be durable and corrosion-resistant. Look for steel construction and a tough powder-coat finish. Steel carts typically provide higher load capacities than plastic, aluminum, or wire alternatives. 
• Controls: Push bars, contact points, comfort. For optimal ergonomics, order pickers should be able to push carts by grasping them in the ergonomic power zone, close to the body between the shoulders and the knees. Curved push handles with comfortable molded grips make Stock Picking Carts from Solus Group safe to operate throughout an entire shift, day after day. The smooth, solid frame of an Order Picking Cart, meanwhile, gives every worker a contact point that fits their body perfectly.
• Extras: Fork pockets, integrated step ladders, customization. Depending on the application, you may look for additional features in a warehouse picking cart. Stock Picking Carts include an integrated step-stool, allowing pickers to reach objects from higher warehouse shelves without stretching or reaching. Order Picker Carts are fitted with welded fork pockets, making them versatile, forkliftable order picking carts. And Solus Group will work with manufacturers to develop custom order picking carts to match any application.

Before making any purchasing decisions, gather data about specific needs: What’s the average size and weight of an order? How many orders per trip will pickers collect? Do you sometimes handle unconventional products that may require specialized material handling equipment?

Next, consider the environment your carts will operate in. Will you use them in narrow-aisle warehouses , stock rooms, production floors, or other environments? The answer could influence your choices based on turning radius, cart size, and overall capacity 

Picking Carts for Warehouse Floors Vs. Order Picker Carts for High Shelf Access

It's also a good idea to think about how your carts will interact with other material handling equipment, especially forklifts. There is a difference between order picking carts and order picker carts. The term "order picking cart" is just what it sounds like: a cart for order pickers to use as they pick orders. It's basically a synonym for Stock Picking Carts, and may also be used to describe tote picking carts and bin carts.

While an Order Picker Cart is also used to collect items from warehouse shelves, it's designed specifically as an attachment for order picker trucks.

These specialized forklifts place an operator platform right behind the forks. The operator rides the forks up and down to access higher shelves. Order Picker Carts attach to the truck's forks to give the operator a place to put the items they're picking from those high shelves.

Once the orders are picked and the operator lowers the Order Picker Cart, then they can roll it via casters, just like any cart. Understanding this difference between order picking carts and Order Picker Carts can help you choose the right equipment every time.

Contact Solus Group to learn more about choosing pikcing carts for warehouse environments. In addition to Order Picking Carts and Stock Picking Carts in a variety of sizes and configurations, Solus Group features a full range of Material Carts and Warehouse Trailers proven to boost throughput in warehouses and fulfillment centers across the globe. To learn more about warehouse picking carts and other material handling solutions from Solus Group, call us at 314-696-0200 today.