The Ultimate Guide to Ergonomic Trolley Design

Published September 12, 2024

Trolleys are essential tools used in many industries including retail, warehousing, manufacturing and healthcare. They help us move goods efficiently. However, if they are not designed well, they can cause strain and discomfort.

Therefore, having a comfortable trolley is crucial because it affects productivity, reduces tiredness and helps avoid long term health issues. Continue reading the blog to learn about the key factors that make trolleys more comfortable to use.

What is ergonomics in trolley design?

Ergonomics refers to designing equipment to match how people use it comfortably and safely. If we talk about trolleys, ergonomics focuses on making pushing and pulling as easy and efficient as possible. If trolleys are not designed well, they can not only cause strain but can also lead to injuries and decreased overall productivity.

What are the key factors in ergonomic trolley design?

Here are some things you should think about to design comfortable and functional trolleys:

Trolley size and shape

Dimensions

Larger trolleys can carry more items but are heavier and harder to move. As a result, they might not be the ideal choice to make pushing and pulling easier.

Height

The height of the trolley affects how comfortable it is to push or pull. A good height prevents you from bending over or reaching too high. This helps avoid back and shoulder pain.

Handle height

Adjustability

The height of the handle is crucial for comfort. A handle that is too high or too low can lead to poor posture and strain. Therefore, ideally, the handle should be adjustable to fit different users and make pushing or pulling easier and more comfortable.

Caster wheel specifications

Wheel Diameter

Larger wheels usually make it easier to move a trolley, especially on uneven or rough surfaces. They roll more smoothly and require less effort to get going. On the other hand, smaller wheels are better for tight spaces where you need precise control.

Material

The caster wheel material affects how well they work on different surfaces. Soft wheels like polyurethane caster wheels are better for uneven or delicate surfaces because they offer a smoother ride and reduce bumps. On the other hand, hard wheels like Nylon last longer due to their durability on rough surfaces.

Swivel VS rigid casters

Since swivel caster wheels can turn in any direction, they enhance maneuverability, especially in tight spaces. However, they might need more effort to start moving. If we talk about rigid casters, they only move in a straight line but make pushing and pulling easier once you are moving.

Optimal trolley and caster wheel configurations

Based on our research and experiments, we have found that certain configurations of trolley size and caster wheels work better for different needs. Here is a look at what works best:

Small trolleys

Size and dimensions

Wheels with a diameter of at least 125 mm are best for trolleys that are up to 1 meter long and 0.5 meters wide.

Wheel type and benefits:

  • Swivel wheels: These are ideal for tight spaces where you need to make sharp turns. Swivel wheels improve maneuverability but might require a bit more effort to get moving.
  • Soft materials: Wheels made from softer materials like PU offer a smoother ride on uneven surfaces. It makes them easier to handle and less bumpy.

Handle height: The handle should be at a height that allows users to push or pull comfortably without straining their back or shoulders.

Medium trolleys

Size and dimensions

For trolleys ranging from 1 to 1.5 meters in length and 0.5 to 0.75 meters in width, wheels with a diameter of around 150 mm work best.

Wheel type and benefits:

  • Combination of swivel and rigid wheels: This configuration balances maneuverability and stability. While swivel wheels can handle tight turns, rigid wheels provide stability during movement.
  • Material Choice: A mix of materials can be used based on the surface conditions you will use the trolley on.

Handle Height: Adjustability is key. Ensure that the handle is set at an ergonomic height to enhance comfort and reduce strain during use.

Large Trolleys

Size and Dimensions

Use wheels with a diameter between 175 and 200 mm for trolleys over 1.5 meters long and 0.75 meters wide.

Wheel type and benefits:

  • Larger and rigid wheels: These wheels are designed to support heavier loads and make it easier to start moving. That is why they provide stability and reduce the initial push force required.
  • Durability: Larger rigid wheels are more durable and better suited for handling heavy items.

Handle Height: Ensure the handle is at a comfortable height to avoid excessive strain on the user for large trolleys. Simply put, the height should facilitate a natural and relaxed posture.

Practical tips for different scenarios

In tight spaces

Choose smaller swivel wheels for trolleys used in areas with limited space, such as narrow aisles or crowded workshops. That is because they allow for better maneuverability and ease of turning in tight spots.

Uneven surfaces

If you are planning to use the trolley on uneven or rough surfaces, choose caster wheels made from softer materials. These wheels give a smoother ride and reduce vibrations, thereby making the trolley easier to handle.

Heavy loads

Consider using larger rigid wheels when moving heavy loads, as they help distribute the weight more evenly and reduce the effort needed to move the trolley.

Final thoughts

Getting the design of trolleys and caster wheels right is crucial to making them more comfortable and easier to use. Moreover, choosing the right wheel size and type and adjusting trolley dimensions and handle height can significantly reduce physical strain and improve usability.

Remember, the best setup depends on how you plan to use the trolley. While small swivel wheels are best for tight spaces, larger rigid wheels work better for heavy loads. Make sure you can adjust the handle height to suit different users.

You can design trolleys that not only improve efficiency but also contribute to better health and comfort by following these tips. Lastly, if you need help choosing the right trolley and caster wheel configurations, contact us at Muvall. Our team is dedicated to helping you find the best solution for your needs to ensure a more comfortable and productive work environment.