If you walk into any warehouse, factory, logistics hub, or storage unit, you’ll notice one thing—everyone is always moving something from one place to another. Material handling might look simple from the outside, but it’s actually where most mistakes happen… and where companies lose the most time, money, and safety.
Across industrial hubs like Bhiwandi, Navi Mumbai, Raigad, Ambernath, Umbergaon, Valsad, Daman, Vapi, Silvassa, Billimora, and Mumbai, businesses are slowly finding out that improving material handling isn’t just about organization; it’s about efficiency, cost saving, worker well-being, and smooth operations.
Let’s talk about the 7 most common material handling mistakes we see in real warehouses every day and how to fix them without overthinking.
Mistake 1: Using the wrong storage products
Some warehouses still try to manage heavy industrial loads with cardboard boxes, wooden crates, or metal bins that rust and dent easily.
✔️ Fix
Switch to plastic crates, industrial bins, material handling plastic crates, and plastic pallets, they last longer, don’t break easily, and protect the material much better. It’s a one-time investment that saves money in the long run.
Mistake 2: Ignoring vertical space
Many companies keep everything spread out on the floor wasting 30–40% warehouse capacity.
✔️ Fix
Use stackable plastic crates and industrial bins to use height efficiently and avoid clutter.
Mistake 3: Not thinking about hygiene
Especially in food, pharma, dairy, and packaging industries, hygiene should never be compromised, but storage products often don’t support it.
✔️ Fix
Use non-porous, washable plastic crates and plastic dustbins that don’t absorb moisture or breed fungus and are easy to sanitize daily.
Mistake 4: Choosing heavy storage solutions
Wooden and metal crates increase worker fatigue during manual handling, resulting in slow operations and injuries.
✔️ Fix
Choose lightweight yet heavy-duty plastic crates and bins that are safe, ergonomic, and easy to lift.
Mistake 5: No color-coding or labeling
When every crate looks the same, locating material becomes a daily challenge.
✔️ Fix
Use color-coded plastic crates or add printed branding/labels to reduce confusion and speed up identification.
Mistake 6: Not planning for moisture or weather
During monsoon or coastal weather, wooden and cardboard storage solutions become useless.
✔️ Fix
Use moisture-resistant industrial plastic crates that don’t bend, swell, or weaken, regardless of temperature or humidity.
Mistake 7: Ignoring long-term cost
Some businesses buy cheaper, disposable options without calculating replacements, repairs, and product damage.
✔️ Fix
Invest in reusable plastic pallets and crates that last for years fewer replacements mean lower operating costs.
Small changes → Big results
Material handling doesn’t need expensive machinery to become efficient.
Sometimes the fastest improvement comes from simply replacing outdated handling tools with smarter ones.
That’s why companies across Bhiwandi, Navi Mumbai, Raigad, Ambernath, Umbergaon, Valsad, Daman, Vapi, Silvassa, Billimora and Mumbai are upgrading to:
They’re safer, last longer, and make everyday warehouse operations smoother.
Looking to fix material handling mistakes in your business?
At Pushti Crates & Bins, we help industries choose the right storage solutions based on their load, product type, and operations so your warehouse runs smarter, not harder.
📞 Contact us today and upgrade your material handling to the next level.