How Hamilton Beach Cut Product Damage by 80% with Electric Lift Trucks and Smart Warehouse Design
Hamilton Beach optimized its new distribution center with electric lift trucks and high-density racking, reducing product damage by 80% and doubling e-commerce efficiency while advancing warehouse sustainability and safety.
Hamilton Beach significantly improved operational efficiency and reduced product damage by transforming its distribution center with electric lift trucks, high-density racking systems, and expert warehouse layout design. Relocating operations to a new facility near Memphis, the company partnered with Yale Lift Truck Technologies and Black Equipment to address critical challenges-such as poor storage density, limited operator visibility, high product damage, and the rising demands of omnichannel and e-commerce fulfillment.
The redesigned warehouse features 50 aisles of double-deep racking, six levels high, maximizing vertical space and enabling faster, safer handling of goods. A modern fleet of electric reach trucks, order pickers, and center riders, equipped with Yale Vision telemetry and fork-level cameras, replaced the older internal combustion engine (ICE) units. This shift not only supported a 274% increase in picking efficiency, but also reduced annual product damage by approximately 80% and contributed to a 75% cut in utility costs, demonstrating the ROI of electric warehouse equipment in high-volume operations.
In addition to operational gains, the new distribution center helped Hamilton Beach advance its goals for sustainability and workplace safety. The elimination of ICE forklifts reduced emissions and noise pollution, while smart racking configurations improved operator visibility and ergonomics. With the ability to opportunity charge during breaks and shift changes, the electric fleet maintained 20-hour daily operations without complexity or downtime. This transformation positions Hamilton Beach as a leading example of how data-driven decisions, advanced warehouse engineering, and electric fleet technology can future-proof supply chains for modern retail and direct-to-consumer logistics.
