How to configure a picking trolley for multi-order picking

What does multi-order picking with a trolley achieve?

In multi-order picking, one operator collects several orders on a single round. Each order gets its own container on the trolley, so the route through the warehouse is walked once instead of four to eight times.

Travelling accounts for up to 50 % of picking cost, the single biggest factor. Bundling four to eight orders cuts the share of unproductive walking noticeably, in practice by around 30 %. The condition is a trolley whose number of containers matches the average order size.

• One container per order prevents mix-ups when sorting.
• Coloured or numbered positions speed up put-away.
• Short, compact trolleys turn more easily at aisle ends.
• Adapt the batch size to aisle width and floor surface.

How many container levels and which format?

Levels determine capacity and ergonomics. Three to five levels are common for Euro containers of 600 x 400 mm or 400 x 300 mm. An ergonomic pick height matters: frequently grabbed containers belong in the zone between 75 and 140 cm.

Tilted or removable levels ease grabbing and transfer at the packing station. An aluminium or steel frame carries 150 to 250 kg of total load without twisting while the trolley is in motion.

Which swivel castors and running properties matter?

Castors decide smoothness and effort. For long pick routes, swivel castors of 125 to 200 mm diameter are recommended: larger wheels roll over joints and thresholds more easily and lower the push force noticeably.

• Two swivel and two fixed castors for stable straight tracking.
• Alternatively four-way steering for tight manoeuvring at the rack.
• Locking brake or total-stop on at least one castor.
• Polyurethane treads for quiet running and floor protection.
• Ball-bearing forks reduce push force over the long term.

Check the total load capacity of the chassis with reserve for the payload. Soft PU treads run quietly and protect screed or industrial floors, hard castors roll more easily but transmit more vibration to the load.

How do document and scanner holders support the route?

Holders for documents, tablet and hand scanner keep both hands free for grabbing. An A4 clipboard or an angled document rest at eye level saves bending and searching, and a fixed scanner holder prevents setting down and dropping.

• Tray for pen, labels and packaging material.
• Hooks for gloves, cutter or adhesive tape.
• Handle with anti-slip grip for long pushing.

Frequently asked questions