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 automated material handling systems into your facility enables you to upskill your workers, moving them from hazardous material handling roles into areas that can add more value to your company – areas like quality control and process improvement. Isthmus can design a custom automated material handling solution that maximizes the consistency, efficiency, scalability, and safety of your entire production process.
Material Handling Automation Capabilities
Custom material conveyance & transfer
Automated material handling systems can move your materials with speed, precision, and control that were previously unheard of. Isthmus can design custom automated material handling solutions to perfectly suit your facility and materials.
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 that you will receive a turnkey system backed by our extensive controls expertise to create a seamless interface with third-party equipment and robotics. Isthmus automated material handling processes create a much safer and more efficient workplace.
Advantages of Automated Material Handling Systems
Increased Safety
Material handling automation streamlines your entire operation and facilitates an ergonomically optimized environment. Automation of material handling allows you to remove employees from precarious manual work and place them in roles that add value to your business.
Increased Quality & Consistency
Automated material handling equipment performs with repeatable consistency and at a rate much faster than human workers. This eliminates bottlenecks and ramps up your production capacity.
Lower Costs
In addition to the savings that come along with an increased production capacity, automation also reduces the amount you spend on manual labor, minimizes waste, and lowers the amount of injury claims by removing operators from unergonomic/unsafe operations.
Common Automated Material Handling Systems Questions
What types of automated material handling systems do you offer?
Isthmus offers a wide range of material handling automation solutions. We can integrate automated conveyor systems, curing systems, kitting and sorting systems, and machine tending systems.
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?
Material handling system automation is a major up-front investment. We can’t predict a specific cost, since that depends on the amount of automation equipment we implement and the level of specialization. Our team will work with you to scope the project and optimize the ROI for your application.
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 hit a ceiling on production capacity in your space? Is the quality of your product inconsistent? Does your current system take too much time between storage and production? These issues can paralyze your business if they continue unaddressed. Implementing a custom material handling system will not only remedy these issues, but position your business to flourish without adding 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.