Tugger Machine

Tugger machines are efficient tools in various logistics environments, including large industries, factories, and airports. They move large quantities of loads and can be pulled by a towing vehicle or manually moved.

If you handle multiple goods that often need to be transported simultaneously, you should consider tugger machines. They are also used in warehouse order picking and to deliver goods to various workstations around the facility.

Tugger trains or tugger machines are transportation vehicles that you can use in various environments, including manufacturing, to quickly and efficiently move goods over long distances or to various workstations. With the tugger machine, you can reduce your runs while ensuring your operations run smoothly like a well-oiled machine.

Our tugger machines are fitted with a powerful coupling arm that allows tugger carts to be connected to multiple carts and the towing vehicle. If the operation is not substantial, a towing vehicle can be used as the driving force or manual force.

How Do Tugger Machines Work?

Tugger machines are versatile and have applications across various industries, such as distribution, logistics and manufacturing.

For the tugger machine to work efficiently, your facility needs three key areas: the replenishment, delivery, and lineside areas.

Replenishment area

The replenishment area is where the product is being delivered to operators is being prepared. This can be in a warehouse, supermarket, or kitting area. The replenishment area needs to have clear and strong information about the lineside area so the tugger is loaded with the right materials to supply at the different stops.

Delivery Isle

The delivery aisle itself forms the path the tugger machine will follow on its route. Think of it as train stops. The route needs to be well planned, so the delivery aisles shouldn’t be taken for granted if you’re going to get the most out of the tugger.

If you have a large operation with multiple people on the floor, it is important to have designated areas for the tugger machine that are separate from where other people are walking. Signage for the drivers and pedestrians helps prevent accidents while the tugger machine is on the move.

Lineside staging

The lineside is the zone between the delivery aisle and the operator’s workspace. It’s usually represented as a simple rectangle but could take different forms depending on your industry. This is where the different orders are processed and offloaded from the tugger carts. Lineside staging should be a well-controlled area with minimal traffic and be safe for the operator.

Depending on your industry and how elaborate your delivery system is, the lineside can be in the form of flow racks or flow chutes. However, other systems also use cart staging lanes, especially for facilities that handle large parts or kit carts.

Benefits of Using Tugger Machines

Tugger machines may look like elaborate handling equipment that require careful planning, but they also present elaborate benefits to operations that successfully incorporate the tugger into their operations. The benefits of tugger machines include:

Efficient goods flow

Tugger machines provide an efficient internal support transport system. They allow you to move multiple carts in succession, saving you the trouble of making multiple trips so employees can move larger quantities at once. They also reduce movements and shorten the duration of the process, helping to improve productivity and efficiency.

Flexibility and adaptability

Certain operations are most practical for incorporating tugger machines. However, they can be adapted to the specific needs of many logistics environments. The machines can be configured with different accessories and towing vehicles to suit different applications and needs and move a wide range of goods.

The adaptability of tugger machines means they can be used for more than moving items. They can also be used for segregation applications, simplifying operations and making your staff more efficient.

Ergonomics

Tugger machines are designed to reduce the physical strain on employees. They minimise manual lifting of heavy goods and pushing of heavy loads, saving employees from the trouble of having to move the loads themselves. As a result, they put less strain on their bodies, joints and muscles, reducing their risk of injury.

Cost savings

The initial cost of a tugger machine can be substantial. But over time, the system can help you make considerable financial savings. The tugger machine can help you automate your delivery process and reduce the need to use expensive, maintenance-intensive equipment such as forklifts, manual labour, and other equipment.

Using tugger machines can lead to lower maintenance costs and fewer accidents, faster and more efficient operations, and greater output, which can increase a business’s profitability.

Common Applications of Tugger Machines

Manufacturing and Assembly

Tugger machines are most commonly used in manufacturing and assembly lines, but this is not the only place where they transport raw materials, parts, and components from one stage of the production process to another.

By using the tugger machine, manufacturers can reduce production processes and reduce the time spent walking between stations by the works.

Warehousing and Distribution Centres

You can also incorporate tugger machines in warehouses and distribution centres. The machines can streamline materials handling, carry inventory across long distances and between storage areas, and make it easier to stock and retrieve goods.

Because of the ability to couple multiple carts at once, you can make more efficient use of resources and reduce the need for manual labour and forklifts.

Automotive and Heavy Equipment Industries

The automotive industry can also benefit immensely from using tugger machines. Assembly lines for vehicles and other heavy equipment often require the transportation of significant bulky components. You can buy a tugger machine with carts that are customised to carry heavy loads or large parts. The tugger machine can be beneficial in environments where forklifts might struggle because of their size or because of space or manoeuvrability constraints.

Tugger machines can also be used in the food and beverage industry in areas that require quick and efficient restocking of raw materials, finished products and ingredients.