Build Your Own Picking Cart

Guest blog from MHI Member Company New Age Industrial

Trying to design the perfect picking cart on your own can be extremely difficult. You might spend a lot of time thinking about your specific needs for the cart and creating what you think is ultimately the best design. Then, you have one built, only to find out that you forgot to include something important. This can be extremely frustrating, not to mention, a waste of time and money. Working with a manufacturer to create a custom cart is a great option, allowing you to create the perfect picking cart to fit your specific needs.

Choose a Base & Casters

A good starting point for a custom picking cart is choosing its base and caster types. There are three basic wheel configurations: 4-wheels, 5-wheels, and 6-wheels. The 4-wheel configuration typically has two rigid casters on one end and two swivel casters on the other. For a 5-wheel configuration, we recommend a center, spring-loaded caster to provide zero-turn capability while maintaining a stable base. Lastly, the 6-wheel configuration normally has two sets of swivel casters on both ends and two rigid casters placed in the middle to provide zero-turning. Sometimes a 6-wheel cart, however, will rock slightly on the end.

Determine Shelf Types

Once a base and caster configuration have been chosen, the next step is to determine which shelf types to add to it. When selecting shelving styles, it’s important to consider what items will be picked using this cart. Heavy-Duty (HD) Shelves are tough enough to hold large boxes. T-Bar Shelves have evenly spaced, perpendicular slats ideal for smaller items. Lastly, Solid or Solid Brute Shelving accommodates individual small items that might otherwise fall through slats. Those with a marine edge will also contain liquids in case of a leak. With solid brute shelving, the top is easily removable for cleaning or replacement. Feel free to mix and match shelf types instead of choosing just one.

Select Number of Shelves & Spacing

As you approach the finish line, there’s only a few things left to decide. Select how many total shelves are needed and how much space is needed between each shelf. This may vary depending on product types and heights to be picked. Based on this important information, upright shelf posts, typically ranging from 12 to 96-inches in height, will need to be added. Some manufacturers offer shelves and posts that are fully adjustable, making them even more versatile. This allows a picking cart to evolve with an organization’s ever-changing needs.

Accessorize the Cart

Once all the main components are selected, there are a variety of useful accessories that can be added to a picking cart to really make it your own. We always recommend adding a handle for easy maneuvering and proper ergonomics. Some deluxe handles even contain document trays and miniature desks. Other options that can be added include document trays, RFID scan gun holders, hanging trash cans and more.

Once a picking cart has been designed to fit your exact needs, it can be manufactured. Upon completion it’s time to use it, test it, and decide what features you love most. With this information, along with any other requests, you can confidently advise a manufacturer of your choosing to build a solid, fully welded cart tailored to your organization, or perhaps order a fleet of the same ones.

For more information about New Age Industrial and their products visit