TPT250

CHAPTER
5
UNIT
LOAD/MATERIAL 1

HANDLING
 LEARNING
OUTCOMES
Upon completing this chapter, students should be able to:
• Understand the meaning of Unit Load Concept and
Material Handling
• Define various types of container
• Describe the functions of palletization
• Explain the various types of material handling
equipment used to handle and carry goods
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UNIT LOAD CONCEPT
▪ Unit load concept is where several units of goods
are combined and move as a single entity.
▪ This concept is relevant to most kinds of goods
and products.
▪ Many producers prefer this concept due to its
advantages.
▪ Example: hundred cans of juice put into a carton
and carried as once carton instead of individual
cans.

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 ADVANTAGES DISADVANTAGES

The assembly and disassembly

Standardized handling equipment
costs are high. Wrapping and
(by using standard equipment pallet,
unwrapping of the goods
crane and forklift)
might be costly.
ADVANTAGES & Standardized storage equipment Initial cost of container is
DISADVANTAGES OF (standard size of goods, standard expensive. Not all producers
equipment to have in the warehouse can afford to use containers
UNIT LOAD or distribution center) system.
Reduced information and control
burden in the data system since High cost of empty container
items are combined as a single handling and disposal.
units.

Efficient pace utilization, due to Inefficient micro space

standard size of pallets, boxes or utilization since it is larger in
containers that help in fully utilizing size, hence cannot be stored in
the space to store these products. small or limited spaces.

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TYPES OF UNIT LOAD
Cardboard boxes/cartons
• More protective and effective, can be
stored on racks or pallets.
• Normally used for food and beverages
products

Sacks
• Commonly used for loose products
such as grains, flour, sugar and etc.
• Cheaper compare to other unit load but
gets easily damaged during in transit.
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TYPES OF UNIT LOAD
Pallet
• The most versatile unit load system and it is made
from wood or metal.
• Can be picked up by using forklift or any mechanical
device.
• All goods can be transferred by using pallets.

Stillage
A pallet with a cage or sides or some form
of support specifically tailored to the
material it is intended to carry.
Some are designed stackable, some are not
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MATERIAL HANDLING
▪ Material handling is an important element in
transport and logistics because it involves how to
move goods.
▪ Can be divided into two categories – fully
automated or non-automated systems.
▪ The unit of load concept is the concept where
goods are moved in large quantities but in single
units.

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 OBJECTIVES DESCRIPTIONS
• Total distribution cost is calculated from the point of
production to the point of consumption.
To reduce total • Cost involves transportation cost, inventory, warehousing,
distribution cost packaging and others.
• To reduce the distribution cost, producer must first reduce
OBJECTIVES OF the cost of any elements along the chain.

MATERIAL To achieve optimum

space requirements
• Using material handling will increase the space utilization,
especially in warehouses.
HANDLING • Material handling involves choosing based on the types of
To reduce damage and goods. Therefore, organization will normally choose
waste equipment that produce less impact on the goods being
moved.
• To load and unload faster, able to move big and heavy
To improve efficiency
cargo more efficiently
To improve the • Distribution pipeline can be understood as the end-to-end
distribution pipeline flow of resources in the distribution network.
• Helps to reduce accidents at work place.
To create better
• Creates safe working environment for workers especially
working conditions
those who involved with goods handling.

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AUTOMATED VS
TRADITIONAL
MATERIAL
HANDLING

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 TYPES OF MATERIAL
HANDLING EQUIPMENT
Roller conveyer Wheel conveyer Belt conveyer

Roller conveyer is Depends on power Goods move as the

more flexible equipment to move belt moves. Most
compared to other goods. Sometimes common powered
conveyer. It makes wheel conveyor is conveyor system,
use of gravity to combined with versatile and least
move goods. another types of expensive.
conveyer.

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 CONTINUOS MOVEMENT

FIXED PATH
CHARACTERISTICS
OF CONVEYORS VERY LIMITED ACCESS AREA

VERY HIGH HARDWARE COST

ASYNCHRONOUS vs. SYNCHRONOUS

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CRANES AND HOISTS
▪ Cranes and hoists are another types of material
handling equipment normally used to handle
container or large cargoes
▪ Cranes can only be used within limited areas
such as ports.
▪ Also known as overhead devices.
▪ Intermittent movement

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TYPES OF QUAY CRANE RTG CRANE STRADDLE
CARRIER
CRANES & • Most common • Used in
cranes used in multimodal • A freight carrying

HOISTS terminal. operations to stack vehicle that carries

or ground its load underneath
• It can cater for all containers. by "straddling" it,
types of container rather than
regardless of its • Normally used to
arrange containers carrying it on top
weight like a conventional
from vessel to
yard truck.

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 INDUSTRIAL TRUCKS
▪ Used to move materials over variable (horizontal) paths
with no restrictions on the area covered (i.e., unrestricted
area)
▪ Provide vertical movement if the truck has lifting
capabilities
▪ Used when there is insufficient (or intermittent) flow
volume such that the use of a conveyor cannot be justified
▪ Provide more flexibility in movement than conveyors and
cranes
▪ Not licensed to travel on public roads—"commercial
trucks" are licensed to travel on public roads 14
CHARACTERISTIC OF
INDUSTRIAL TRUCKS
▪ Pallet/Non-Pallet: Does the truck have forks for handling pallets,
or does the truck have a flat surface on which to place loads
▪ Manual/Powered: Does the truck have manual or powered
vertical (lifting) and/or horizontal (travel) movement capabilities
▪ Walk/Ride: For non-automated trucks, can the operator ride on
the truck (in either a standing or sitting position) or is the operator
required to walk with the truck during travel
▪ Stack/No Stack: Can the truck be used to lift loads for stacking
purposes.
▪ Automated: Is the truck automated so that it can transport loads
without requiring an operator.
▪ Non-Automated: direct labor cost of operator is by far the largest
cost to operate a non-automated truck. 15
 AUXILIARY
EQUIPMENT
▪ Used to support the operator to handle goods.
▪ The main function is to make the material handling
process smooth.
▪ Examples of auxiliary equipment include barcode
reader, radio frequency terminals, stretch wrappers,
palletizer and lift tables.

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 TYPES OF AUXILIARY
EQUIPMENT
Barcode reader Radio Frequency Terminal Stretch Wrapper

- Used in inventory - Widely used in the industry - Used to wrap goods in

management to keep especially in warehouse, plastics film.
information on goods. ports and DC. - Producers use this to reduce
- Data received from barcode - Can eliminate damage to goods in transit.
is more accurate and reliable. communication barriers - The cost is quite expensive
- Improves the efficiency and among workers. since it uses high quality of
effectiveness of an inventory - Reduces the problem of plastic in large qty.
system. losing data in all - Manual, semi-automatic and
transactions. automatic wrapper
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 TYPES OF AUXILIARY
EQUIPMENT
Palletizer Lift table Robot

- Automatic machine that - Widely used in warehouse - The most efficient

stacks goods or products on a or factory plants. equipment but the most
pallet. - It function to lift goods or expensive cost.
- Reduce the time taken in put away and order picking. - System depends 100% on
handling goods. - It reduces the workers back computer operations.
- Helps operator to save pain while lifting heavy - Suitable to lift heavy
labor costs. goods. products or material in
production line.
- Giant companies use a lot
of robots.

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 USE THE RIGHT METHOD
Refers to the technique in handling material, based on its category or type
of goods. The wrong method used would damage goods and products

TO PROVIDE THE RIGHT AMOUNT

NINE (9) RIGHTS Refers to the correct quantity to carry at one particular time. Using the appropriate
material handling equipment will increase the capacity of goods moved. Indirectly,

IN MATERIAL
this will reduce the transport and logistics costs.

HANDLING OF THE RIGHT MATERIAL

Refers to the selection of the correct equipment to handle material. For
example, grains or flour involves movement by a fully automated
conveyor system which will reduce time and costs.

TO THE RIGHT PLACE

Goods need to be sent to the right place where it is demanded. Material
handling allows easy movement of goods for shipment and storage.

AT THE RIGHT TIME

Refers to the specific time to transfer goods especially for time-
sensitive and perishable goods. Goods need to arrive on time at the
destination.
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 IN THE RIGHT SEQUENCE
Refers to the movement of batch for the material, especially during
the production process.

IN THE RIGHT POSITION

NINE RIGHTS IN Refers to the right of placement or material during production, which will reduce
the problem of inefficient operation in warehouse. It needs a right amount of space.

MATERIAL
HANDLING IN THE RIGHT CONDITION
Refers to the right location to place the right material to avoid
inconvenience at the work place. This allow workers to have enough space
to perform their tasks.

AT THE RIGHT COST

Refers to the total cost after completing the process. Its important to
reduce the material handling cost to the selling price of product is
reasonable.

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 PALLETIZATION
▪ A pallet can be defined as the flat tray to carry goods.
▪ The best method to carry various items of goods in
single entity.
▪ Pallets can come in plastics, metal and wood.
▪ Forklift is used to handle a pallet

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 Wing Pallet
- Designed to have extensions beyond the
bearer to facilitate the use of spreader bar slings
for crane hoisting.

TYPES OF Skeleton Pallet

PALLET - A slatted decks which are cheaper and are
normally used for lightweight goods or
products.

Stevedores Pallet
- Pallets reinforced with steel for the use of
slings in crane lifting

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 Expendable Pallet
- The most expensive type. Normally used to send
goods over a long distance.

TYPES OF Post Pallet

PALLET - Used to carry fragile, awkward shape or crushable
goods and products. Designed with a solid frame to
support the pallet to allow the goods to be stacked.

Box Pallet
- Boxes with three sides or four sides.
- Useful for safeguarding small objects which would
otherwise fall out, or be pilfered.

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 ADVANTAGES DISADVANTAGES
Portability as it eases the movement of Contain hostile insects and plant disease –
goods and products in logistics – facilitate wooden pallet, needs fumigation
unit to be carried in a single unit.
ADVANTAGES & Increase space utilization in a warehouse Wooden pallet are non-durable for a long
DISADVANTAGES to store goods – racking system which
keeps the good temporarily before
time – can get moldy if exposed to
moisture
OF USING PALLET shipment day.
Recyclable as pallets can be melted down, High cost and time spent for wrapping and
recast, sold as scrap material, disassembled unwrapping pallets
etc.
Helps improve the operation movement in
the warehouse, ports and terminals –
allows large quantity of goods to be
transferred at a time.
Less damage as pallets are stronger than
cardboard boxes and plastic wrappers.
Thus we can stack more and keeping
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products from water, dirt and debris.
 CONTAINERIZATION
▪ Containers are steel-framed boxes with a strong floor
and paneled sides, end and roof.
▪ Containers are being secured before shipment by using
container seals.
▪ An important elements in intermodalism as they can
carry various goods at one time in large quantities.
▪ Container units may vary in dimension, structure,
materials and construction.
▪ Various types of container are being used today to
fulfilled the requirement of shipment.
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 TYPES OF
CONTAINER

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 REFRIGERATED
CONTAINER
▪ Temperature-controlled containers.
▪ Used to transfer frozen food items or flowers, fruits and
human organ.
▪ Equipped with refrigeration units which require
connection to the carrying ship’s electrical power
supply.
▪ If there is any multifunction occur, it will cause damage
to the goods carried inside.

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 FLAT RACK
CONTAINER
▪ Flat platform container to carry an oversized cargo.
▪ With inflatable sides, these are simple storage
shipping containers where the sides can be folded
to make a flat rack for a wide variety of goods.

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 OPEN TOP
CONTAINER
▪ Used to carry bulk material such as grains and wheat.
▪ Do not have a solid roof.
▪ This container normally have a removable tarpaulin
roof which can be secured with roof.
▪ The door can also be swung out allowing easier access
to the cargo.
▪ Ideal for bulky cargo such as machineries

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 VENTILATED
CONTAINER
▪ Specialized box used to transport organic cargo with
high moisture content such as coffee and cocoa beans.
▪ Special equipment is needed to ensure sweat is
prevented from forming on the product.
▪ Ventilated containers allow air to flow in to keep the
grains moist.

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 TANKERS
▪ Design to transport liquids and gases.
▪ A temperature-controlled tank containers have special
heating or cooling device.
▪ Tanks are equipped with anti-corrosive materials to
protect materials from damages.

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 OPEN-SIDED
CONTAINER
▪ This type of container have solid end walls and solid
roof panel.
▪ It is designed to have two sets of double doors along the
side of the container.
▪ This allows unrestricted access for loading and
unloading.

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ADVANTAGES ADVANTAGES DISADVANTAGES

& Standardization as it can be handled

anywhere in the world (ISO standard)
Site constraints as it consumes large
terminal space for storage
DISADVANTAGES
OF CONTAINERS
Freight costs can be reduced since High capital investment in order to
items are combined and transferred in provide container handling
large quantities infrastructures such as giant cranes

Intermediate handling eliminates High load factors as sometimes it is

damage, reduce pilferage and provides difficult to transfer goods FCL in one
sufficient domestic packaging. direction, so the possibilities to empty
return are high.

Flexibility where it can be used to carry High insurance rates due to the cost of
wide variety of goods such as the boxes, plus the value of the goods
commodities, manufactured goods, carried is also high.
refrigerated goods etc.

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