What Is a Tugger and How Can It Improve Your Material Handling System

A tugger system is a fleet of vehicles that pull multiple material handling carts in a train. It’s a way to keep products, supplies, and other materials moving — and enhancing efficiency by moving more of those materials in each “run" than what would be possible with human-operated carts and lifts.

Not every facility can utilize tugger systems, but many modern warehouses can, particularly facilities with varied inventories. A well-designed fleet has some outstanding benefits and can provide vital support for lean material flow strategies.

So, is a tugger system a good choice for your operation? Potentially — provided that it’s designed specifically for your operation. Let’s define tugger systems and explore the benefits.

Tugger Systems: Use Cases and Advantages

Traditionally, the way to build a more efficient warehouse was to build vertically. That’s still a worthwhile effort; operations that utilize Vertical Reciprocating Conveyors (VRCs) can store more product, which can translate to greater profits.

But when you build up, you’ve still got to find ways to move products and materials efficiently throughout  your facility. And if you’ve got a warehouse or DC with an extensive variety of products, vertical storage can quickly lead to a honeycombing effect that seriously limits your throughput.

Tugger systems are both an alternative to vertical storage and a way to maximize throughput, regardless of a facility’s storage strategy. Some of the most successful use cases include:

• Small Parts Transport: Tugger systems can move bins, totes, and other containers of smaller items to workstations, with tugger operators performing multiple runs throughout the day to keep workers supplied.
• Order Picking: Tugger systems have caught on in pick-to-cart facilities. They’re particularly capable when paired with Automated Guided Vehicles (AGVs) or robots, though manually operated tugger trains are still the standard.
• Work-in-Progress (WIP) Movement: Tugger operators can move raw materials to assembly stations, limiting the cost of labor and reducing errors.
• Lean Manufacturing: By delivering materials just-in-time, tugger systems are a natural fit for operations that seek to limit inventory.

In each of these applications, tugger train systems work because they’re modular, maneuverable, and flexible. You can combine them with AGRs or AGVs; you can add and remove carts as needed to keep up with changes in your business. They’re also safer for transporting products and materials than forklifts (though you’ll probably still have lift trucks on the floor for certain tasks).

The bottom line: A well-designed logistics train can deliver an ROI almost instantaneously.

Related: Modular Carts for Custom Material Handling Trains

Build a Tugger Train System for Your Operation

Logistics trains are inherently modular, but that doesn’t mean that you can build them through trial and error. You need carts that are designed for the types of products and materials you move on a daily basis. Each load carrier must be suited to your facility, with an appropriate turn radius and adequate support for the items you’re moving.

That’s where an experienced material handling partner can make a difference. At Solus Group, we supply robust equipment that optimizes throughput on day one. Whether you need custom carts for specific types of products or standard load carriers that are fully compatible with your existing tugger train system, we’re prepared to provide solutions.

Options include:

• Quad Steer Tugger Carts (TT-QS) feature axles that steer in tandem, allowing for an exceptional turning radius along the entire train. With capacities of up to 2,000 lbs., they’re configurable to support any types of materials and fully compatible with all types of electric tuggers.
• Center Steer Tugger Carts (TT-CS) utilize a fifth caster that allows the entire unit to pivot in place. As with the TT-QS, they’re compatible with all tuggers, including AGVs and AGRs.
• Dual Steer Tugger Carts (TT-DS) have swiveling front casters and fixed rear casters. They offer a balanced combination of ergonomics during manual use and clear tracking as part of a train
• Industrial Trailers (IT) combine the best features of stock carts and tugger trailers to provide versatile material handling for order picking, line feeding, putaway, and other intralogistics tasks — even in very narrow aisle facilities.

All material handling carts can be customized as needed, and we provide excellent lead times on all customizations. 

To learn more — or to discuss how a tugger train system can slot into your operation — call 314-696-0200 or view our full selection of industrial carts.