Electric Tugger Essentials
Material Handling Tuggers
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What is an electric tugger?
An electric tugger is a battery-powered machine designed to move heavy-wheeled loads. They are known by many names such as ‘electric tows’, ‘electric tow tugs’, ‘pedestrian tuggers’, ‘cart tuggers’, 'walkie tuggers' and ‘powered tuggers’.
As a type of material handling equipment, electric tugs are used extensively within industrial manufacturing environments and in sectors such as retail, biopharmaceuticals, waste handling and more.
Using electric tuggers enables businesses to create processes that are more efficient and safer, enabling a single operator to push, pull and stop heavy loads.
With compact designs, electric tugs are the ideal solution for moving large loads in tight spaces - guaranteeing total maneuverability.
Benefits of an electric tugger
Electric tow tugs can be found in industrial manufacturing environments across the globe, but what benefits do they deliver?
Increase operational efficiency
Reduce manual handling
No operator license required
Zero emissions
Improve workplace safety
Maximize flexibility
Industrial tuggers - An alternative solution to…
Traditional handling equipment – Forklift trucks & electric tow tractors
By keeping loads safely on the ground, electric tuggers offer an effective alternative to traditional material handling equipment such as forklift trucks, pallet trucks and overhead cranes.
With a compact machine footprint, many businesses are opting for electric tow tugs as an alternative to an electric tow tractor to deliver the precise movement of loads in tight or congested areas.
Manual handling solutions
Where wheeled loads were moved manually, an industrial cart tugger takes the strain – increasing safety and reducing the risk of injuries and strain.
Learn more about Manual Handling Solutions
Choosing the right cart tugger or tugger machine
Material handling tuggers are specified on an application basis to ensure any solution delivers quantifiable safety and efficiency gains for you right out of the box. With a wide range of electric tuggers on the market, there are a number of key factors that can influence which is right for you:
Maximum Load Weight
The heavier the total load weight, the more power is needed from the machine to push, pull and stop it, in a safe and controlled way.
This is often referred to as the ‘towing capacity’ or ‘maximum load capability’.
Rolling Resistance
This is the force needed to start a wheeled load moving and is influenced by factors such as floor condition, castor wheels and slopes.
Slopes can have a significant impact on the right electric tugger for an application. A simple rule of thumb, the steeper the slope, the more powerful the electric tug needs to be.
Couplings
When looking at electric tuggers, it’s important to consider how the equipment will connect to your load.
Couplings are the essential part that facilitates this connection, and their design dictates how secure your equipment and load are during transportation.
We offer a range of coupling options across our range of electric tuggers:
Hydraulic clamp
Available on the SmartMover range, our hydraulic clamp creates an unbreakable connection to the load.
Connect directly to your cart or with our available adaptors.
CombiCoupling
Delivering a rigid connection to loads using a male and female coupling system, our unique
Combi Coupling facilitates unrivaled weight-moving capability and maneuverability
Pin coupling
Enabling quick and easy connection to a wide range of industry-standard drawbars and towing arms, the pin coupling is a convenient solution for connecting to multiple loads.
Box coupling
Perfect for applications where movement is on slopes or rough terrain, the BoxCoupling ensures a strong connection to the load, enabling precise maneuverability.
Channel coupling
Facilitating a secure, direct connection to your trolley, the ChannelCoupling can be used on multiple loads without the need for modifications.
Hydraulic options are available for added load security.
Custom coupling
Designed around your needs. Our experienced engineering team are on-hand to create custom coupling solutions that prioritize security, ease-of-use and suitability.
Material types & environmental ratings
The construction material needed for an electric tug or specialist environmental protection such as required ingress protection (IP) or explosion-proofing all impact the specification.
Electric tuggers vs electric tow tugs
The phrases electric tugger and electric tow tug are often used interchangeably, leading to confusion around what the differences are.
The two terms describe two different machine designs designed for different jobs...
Traction is essential when it comes to moving heavy loads and the key difference between an electric tugger and an electric tow tug is how they generate traction and in turn, move loads.
Electric tugs utilize a weight transfer system and a specialist coupling set-up designed to get your load moving, steer it, and bring it to a controlled stop. Weight transfer involves a machine transferring an element of the loads' weight down onto the drive wheel of the machine to gain traction, allowing compact machines to move very heavy weights.
Unlike tuggers, which utilize a weight transfer system to generate traction, an electric tow ultimately uses its own weight to gain traction and get loads moving.
Technology & control options
Electric tuggers are available with various technology and control options, designed to maximize the benefits of safety and efficiency. From pedestrian-operated electric tuggers to fully autonomous solutions - there are electric tow tug solutions to meet every requirement.
Remote control operation provides operators with complete flexibility, allowing them to have an ideal vantage point when making a movement delivering maximum visibility.
Innovative MultiLink technology on our PowerSteered range allows multiple machines (up to 12) to work in synchronization via one remote control, perfect for the movement of large, awkward loads that require precise positioning.
Take advantage of Line Follow navigation on AGV electric tuggers to easily automate the repeated movement of heavy loads to drive operational efficiency. Or benefit from a totally integrated and autonomous solution with a full AGV system that utilizes intuitive natural navigation.
Electric tugger machine safety features & options
Any material handling equipment needs to maximize operator safety, particularly when moving heavy loads within congested and pedestrianized areas.
Our high-quality electric tow tugs boast all the safety features detailed below, ensuring that operators and pedestrians remain safe at all times.
Ergonomic controls
Emergency stop
Automatic tiller cut off
Anti-crush button
Castor guard
Visual safety aids
Audible alerts
Adjustable speed
Industrial electric tugger applications & industries
Working with many Fortune 500 companies to slimline their operations and improve safety has enabled us to work in a diverse range of industries from biopharmaceuticals to industrial manufacturing.
The ultimate guide to electric tuggers
Electric tugger essentials
Looking to understand electric tuggers in a little more detail?
We’ve compiled some helpful resources to get you started, covering everything from how they work, different types of batteries, getting the right connection point and more…
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What is an electric tugger?
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5 benefits of electric tuggers
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Do you need a license?
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How electric tuggers work
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Batteries & charging guide
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Couplings & connections
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Castor wheel explainer
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Frequently asked question
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Why businesses use electric tuggers
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Pedestrian operated vs remote control
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Automation & remote control options
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Tuggers vs tows
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Pricing guide
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Walkie tuggers
Your Questions, Answered - Electric Tugger Machine FAQs
- Load weight and route
- Run speed
- Battery specification/size
- Environmental conditions such as temperature
No, you do not need a license to use an electric tugger. This is one of the many reasons industrial manufacturers are increasingly opting for electric tugs to create fork-fee environments.
Unlike forklift trucks, electric tow tugs don’t lift loads.
With an electric tugger, you no longer need to wait for the availability of a licensed forklift truck driver to move a load.
Like any battery, the battery life of an electric tug or electric tow is determined by usage, specification, and environmental factors. Battery life can be influenced by variables such as:
We provide a runtime figure on each of our product pages.
Yes, all MasterMover machines will work on slopes. The maximum angle our tugs are capable of clearing, on average, is 8°.
It is important to remember that for every degree of slope involved, the maximum load capacity of the machine is reduced, just as pushing a car on the level requires less force than on a slope.
Therefore, if the weight of the load is already close to the maximum capacity of the machine a more powerful tugger may be needed to move the load on a slope.
Yes, all our electric tow tugs are suitable for both indoor and outdoor use. Our AllTerrain tow tug range is the ideal solution for the most challenging of environments.
For applications where a standard solution isn’t the right fit, we have a dedicated engineering team on hand to create custom solutions. With 25 years of industry experience in providing customized solutions, you’re in safe hands with MasterMover.
We're here to help
If you’re looking to improve safety, remove the risk of injury and unlock greater operational efficiency, we’re here to help. Speak to our team to discuss your application.