Material Handling
Automated Material Handling For Manufacturers
Material handling is the #1 source of workplace injuries in the U.S., accounting for $13.7 billion in costs in 2025 alone. Implementing a material handling automation system helps manufacturers reduce manual handling, improve worker safety, and move employees from hazardous, repetitive tasks into higher-value roles such as quality control and process improvement. Isthmus designs custom automated material handling systems that maximize consistency, efficiency, scalability, and safety across your entire production process.
Material Handling Automation Capabilities
Custom material conveyance & transfer
A custom material handling automation system can move materials with greater speed, precision, and control than manual processes. Isthmus designs each automated material handling system to match your facility layout, production goals, and material flow requirements.
Accumulation systems
Automated accumulation systems utilize sensors to manage product flow and processes running at different speeds. These systems maximize efficiency by eliminating bottlenecks, stoppages, and waste.
Flexible palletizing systems
Adopting flexible palletizing systems boosts your operational efficiency, handling multiple SKUs and pallet patterns without no need for manual changeovers or slowing down.
Robotics & systems integration
Partnering with an automation engineering firm like Isthmus ensures you receive a turnkey material handling automation system backed by extensive controls expertise. We seamlessly integrate robotics and third-party equipment to create an automated material handling system that improves safety, efficiency, and overall production performance.
Advantages of Automated Material Handling Systems
Increased Safety
A material handling automation system streamlines your operation while creating a safer, more ergonomic work environment. An automated material handling system removes employees from repetitive and hazardous manual tasks, allowing them to focus on higher-value work that supports your business.
Increased Quality & Consistency
An automated material handling system performs repetitive tasks with consistent accuracy and at speeds that exceed manual operations. The result is fewer bottlenecks, improved product quality, and greater production capacity.
Lower Costs
Beyond increasing production capacity, a material handling automation system lowers labor costs, minimizes waste, and reduces workplace injuries by removing operators from repetitive and ergonomically challenging tasks.
Common Automated Material Handling Systems Questions
What types of automated material handling systems do you offer?
Isthmus designs custom material handling automation systems for a wide range of manufacturing applications. Our solutions include automated conveyor systems, curing systems, kitting and sorting systems, machine tending systems, and other automated material handling systems tailored to your production process.
Which parts of my material handling system can be automated?
Isthmus can automate key parts of your material handling system or transform your entire material handling operation with a fully automated system. The solutions we propose depend on the needs of your unique system. Material handling systems typically automate repeated manual processes that either occur at a high volume or speed, pose ergonomic or safety risks to operators, or require precision, quality control, or traceability. If your facility can improve in any of these areas, contact us to learn more.
How much does material handling system automation cost? When will I see the ROI?
Investing in a material handling automation system is a significant upfront decision. Costs vary based on the level of automation, system complexity, and customization required. Our engineers will work with you to scope the project and design an automated material handling system that delivers the strongest possible return on investment.
Does Isthmus outsource any part of the custom material handling system designing and building process?
Isthmus does not outsource. We have all of the required engineering and assembly resources in-house at our Madison, Wisconsin facility.
How do I know if my business needs material handling system automation?
Have you reached the limits of your production capacity? Are inconsistent product quality, excessive manual handling, or slow material movement impacting efficiency? A custom material handling automation system can solve these challenges by improving throughput, reducing labor demands, and positioning your facility for long-term growth without requiring additional space.
Can I automate my material handling system without disrupting my current system?
Isthmus can design a material handling system implementation plan that minimizes disruptions and downtime as much as possible.
Pharmaceutical Packaging
Custom product and literature placement, as well as unique labeling requirements for OTC packaging.
Diagnostic Device Packaging
Vision-guided positioning of sealing gaskets, custom box-forming, and placement of multiple literature inserts into a medical testing kit.
Pest Control Device Packaging
Assembly of a point of purchase display package, including custom stations to feed, wrap and weld a safety strap prior to offload.