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Cart Systems: 
A Cost-saving 
Forklift Alternative

In modern-day production environments, forklifts are an inefficient way to move materials—limited in capability and high in risk and cost. Across industries and applications, implementing effective forklift alternatives creates safer and more functional work environments.

Experience the Benefits of a Forklift-free Facility

Cart systems outperform forklifts on your facility floor across three key metrics.

Safety

Forklifts lack many of the uniform driver testing and safety features we expect from cars. In turn, they leave facilities susceptible to worker injuries and product damage. Cart systems are designed with superior safety features.

Cost

Along with high leasing and operating costs, forklifts also result in higher product damages and lower productivity compared to cart systems. Cart systems offer short- and long-term savings in each of these areas.

Efficiency

Forklifts only offer vertical lifting for one item at a time, typically in a pallet load quantity. As a forklift alternative, customizable tugger carts save time and effort by carrying multiple load types at once.

Proactively Protect Against Workplace Accidents

Most forklift accidents are in manufacturing. Forklift alternatives can minimize these risks.

80%

Forklift accidents involve
a pedestrian

110K+

Major forklift accidents
per year

$135M

Accident cost to business
per year

Tugger vs Forklift: A Side-by-Side Comparison

Cost
Efficiency
Customization
Packaging
Automation

Forklift

$9.60 cost per drop
Moves one item at a time
Require costly attachments or extensions for specific applications, which are limited
Typically require wrapping for palletized loads
Automated forklifts are available at a high cost, potentially posing even greater risk and liabilities

Tugger

$4.10 cost per drop analysis for train with tow/hitch carts*
$2.40 cost per drop analysis with mother daughter carts*
Moves many parts at a time by combining bulk, shelf, and kit carts
Small trains of 4-5 carts can be completely customized for your operation at al ower cost, plus cart types can be easily changed over time if needs evolve.
Minomi carts can move mixed parts without the need for additional packaging
Driverless, automated cart flows could be a safer option for transforming material flow in the future—and your operation can start preparing now

Tailored Trains for Your Facility Floor

Areas with low pedestrian traffic and specific movement requirements —such as shipping and receiving—typically remain forklift areas, with additional restrictions and alerts in place to improve safety. For everywhere else, tuggers and customized trains are the superior choice.

At Geolean, we can help you determine which cart types will optimize your material flow. We offer a wide range of ready-to-order and custom-engineered options for daily activities.

Experts You Can Lean On

The Case for Forklift Free

Ready to dive deeper into the advantages of forklift alternatives? See how a forklift-free approach could benefit your facility in this guide by Geolean’s experts.

Implement Forklift Alternatives with Confidence

Transitioning to a forklift alternative requires technical, process, and system adjustments—which can feel like an overwhelming undertaking at first.

Geolean simplifies the process with expert support for:

  • Analysis and diagnostics
  • Change management
  • Solution recommendation
  • Cart and train design
  • Cart system implementation

Plus, we regularly follow up and provide ongoing support services to ensure your success. As your company grows, we can help you adjust or add cart systems to optimize material flow.

Experts You Can Lean On

It’s Time to Take Action on a 
Forklift Alternative

The savings start as soon as you implement a tugger and cart system. Our experts are ready to help you make it happen. Contact us with your questions or to request a quote.