How to Start the Transition from Forklifts to a Tugger Train System

The forklift has been around for a long time and has been used for order picking, item relocation, and general product logistics. It’s practically a staple in logistics operations. But a ‘new guy’ is toppling the old guy from being the king of the warehouse. It’s called the tugger train and more and more companies are adopting this system.

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Why Go Tugger Train?

There’s a developing trend towards reducing forklift usage and even ultimately going completely forklift-free. This is due to a lot of reasons, most notable of which are:

Tugger trains, on the other hand, are getting more popular because of their advantages over forklifts.

  • Consumes less energy. 
  • Saves time. A tugger train can move more than one load at a time by linking multiple carts to a single tugger saving time.
  • Saves money. Tugger trains are cheaper than forklifts. Tugger train operators require less pay than forklift operators.


If you're looking to transition to tugger carts, contact us at [email protected]

Planning the Transition

Going from forklift to a train tugger system is not an overnight process. Planning alone can take months. The actual implementation may take months to complete and years to perfect, doing adjustments as the processes become more mature with time. Here are factors that you need to consider when implementing a tugger train system to replace your forklifts.

Using Space Most Efficiently

If your warehouse space was designed for forklift operation, you might need to make adjustments in order to reduce bottlenecks and congestion on the floor. You’ll need to design routes especially for tugs and carts if you want to improve the materials transport flow. With improved flow come inventory reduction and productivity improvements for your workers. There is also less requirement to buffer unlike when using forklifts.

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Length of the Train

The length of the cart train that the tugger will pull depends on plant size, aisle widths,  tug capacity, type and size of carts, and plant safety regulations. Assembly plant deliveries typically require two to three carts. If sequenced using the last in, first out system, longer trains (around six to eight) is possible as long as there is sufficient capacity in the tug, the steering of the cart is modified properly, and there are large enough aisles to handle the train’s turns. You’ll usually see trains with six to eight carts in warehouses transporting materials to the dock and back. They are also common in put-away and sorting locations.

Cart Types and Configurations

There are different types of carts and configurations that can be used depending on your requirements. Choosing the correct ones will depend on the size, weight, and shape of your load and product, the configuration of the plant, and if a sequencing system is in use.

If you're looking to transition from forklifts to tugger carts, contact us at [email protected]

Not for Vertical Stacking

One advantage of the forklift over the tugger train system is the ability to pick and stack materials vertically. The tugger is not designed for this scenario. You should implement another type of handling equipment like reach trucks or order pickers to safely load and pick vertically.

Tuggers and Carts Beyond the Plant

The usual notion is that a tugger train system is good for plant use only. That is not the case. This system can also move products and materials between the warehouse and the plant. And since you will be moving more load in a single trip, transporting using tugs and carts are more cost-effective.

Effects on Operation Areas

When you replace forklifts with tugs and carts, you need to make modifications on operation areas in order to the new system. That is why it’s highly recommended that you include your plant workers when doing the planning because they are more familiar with the flow and the issues that are commonly encountered during transport.

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Plan Early

Those who fail to plan are planning to fail, that’s a well-known cliché but it applies to transitioning from forklifts to tugs and carts. If you want to succeed with the transition, you need to plan early.

You should list all your goals and analyze the current scenario. You may also use simulations to test your assumptions and confirm which approach to take. Identifying improvement potentials should also be part of the planning process.

If the transition project is huge and involves factors that may hinder production and output, plan the transition in increments. A change in processes translates to work changes for the employees and changes in habits. Doing the transition in one go may be met with resistance. Accomplish small milestones instead to make the transition more palatable.

Going Clean and Green

With all the discussions about environmental changes, emission reduction, and energy-efficient operations, transitioning to the tugger train system is the way to go. Tugs require less power to operate which means less fuel and less emission. There are even tugs that run on rechargeable batteries.

Going from forklifts to tugger train systems need not be painful if you plan accordingly. The benefits are more than worth the cost and time spent during implementation. There are even companies that have decided to retain their forklifts. These operate within the perimeter area of the warehouse for loading to and from trucks while tugs and carts are operated inside the plant. That is power complementing efficiency.

If you're looking at beginning with tugger carts, contact us at [email protected]


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