Shelf heights set from the cartons and pick sequence, not from a catalogue
Shelf pitch usually follows your tallest regular carton plus clearance; spacing that works for shoe boxes uselessly wastes air when the mix includes larger cartons.
Order Picking Cart / Warehouse Picking Trolley
Custom Order Picking Trolleys for Warehouse Operators
Built-to-drawing picking carts for picking towers, batch picking, replenishment and packing lines. The useful dimensions of a picking cart are not its outside size — they are the shelf height an operator can reach without stooping, the usable depth for your cartons or totes, the handle that clears the aisle, and the caster mix that lets one person start and stop the cart loaded. Tell us your carton range, pick face and route, and we build the rest around them.
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Materials: steel, stainless steel or aluminum by project
Load: engineered to your target cargo and route
Wheels: PU, rubber, nylon or pneumatic with brake options
Finish: powder coating, plating, galvanizing or stainless
Product Overview
Built Around Load, Movement, Storage and Safety
Doing Metal can customize trolley structure based on your drawings, product photos, sample design, working environment, and quantity target. We review frame strength, caster layout, platform or shelf design, finish, and packing before quotation.
Buyer Problem and Custom Solution
Off-the-shelf picking carts force operators into compromises: shelves too deep to reach the back of, rails too high to scan over, handles too long for the aisle end, or wheels that need a shove to start when the cart is loaded. Those small frictions repeat thousands of times per shift, which is why picking productivity arguments usually start at the cart.
Doing Metal Solution
Send your carton or tote dimensions, typical pick load and order profile, shelf count, aisle width and turning space, floor condition, whether routes include ramps or thresholds, and the quantity. We review frame width, handle projection, shelf arrangement, caster layout and brake reach, then quote from a drawing. Repeat programmes are quoted from drawings and jigs kept on file, so year-two orders match year-one geometry.
Open or mesh sides that hold cartons without hiding labels
Sides are chosen for containment and visibility at the same time — mesh, low rails or open frames depending on how much the load shifts on the route.
Handle, document shelf and scanner or tablet mount placed for the operator
Handle height, push angle and whether the handle is removable all change turning clearance at the end of a narrow aisle.
Caster mix and brakes sized for loaded starts, stops and aisle turning
A loaded picking cart is started and stopped dozens of times per shift, so rolling resistance and brake reach matter more than top speed.
Workshop Photos
What We Actually Build, Photographed in Our Own Workshop
Every photo on this page was taken in our own workshop or at our customer site. No stock images, no renderings.
A batch in final inspection — repeat orders match the original drawing.
Mesh sides keep loose cartons and totes contained without hiding the labels.
Front view — removable push handle and flat deck for mixed carton sizes.
Rack layout — shelf pitch and guides designed around one specific part family.
The cart is sized for the cartons you actually move, not the other way round.
Bolt-on casters with welded corner gussets — replaceable in your own warehouse.
Customization
Custom Options to Confirm Before Quotation
These options change material use, process route, tooling, assembly time, packing volume, and final cost.
Number of shelves and usable shelf depth
Shelf pitch set from your carton mix
Side rails, mesh panels, dividers or open frames
Handle height, style, removable or folding option
Document shelf, scanner holder, label printer shelf or bin rail
Wheel tread, diameter, brake count and finish
Buyer Decision Guide
Details That Decide Whether This Trolley Will Work in Daily Use
Use this section before sending an RFQ. It translates the search term into the practical design points our team needs to review.
| Decision Area | What to Confirm | Why It Matters |
|---|---|---|
| Carton range | Smallest and largest carton or tote you handle | Decides usable shelf depth, shelf pitch and whether the side panels go higher than the load |
| Aisle | Narrowest aisle and turning space at the ends | Decides frame width, handle projection and caster layout |
| Pick method | Single order, batch, or multi-order with totes | Decides whether you need open shelves, dividers or a tote rack |
| Duty cycle | Starts and stops per shift, route distance | Decides wheel diameter and tread more than load alone does |
Engineering Choices
Key Details That Change Trolley Performance and Cost
Foreign material handling buyers often compare the same trolley by load class, wheel system, ergonomic design, towing method, surface finish, and packing. Confirming these details early helps avoid under-built carts and unnecessary cost.
Frame and Deck
Tube size, plate thickness, reinforcement ribs, weld layout, and deck surface should match the real load, cargo footprint, and impact during use.
Caster Layout
Two fixed plus two swivel wheels, four swivel wheels, brake casters, pneumatic tires, or larger PU wheels can be selected for different routes and floor conditions.
Push, Pull or Tow
Manual push handles, double handles, tow bars, coupling arms, forklift handling, or AGV interface requirements can be reviewed for custom projects.
Safety and Parking
Brake position, side rails, mesh guards, anti-slip decks, wheel locks, and load distribution help make the trolley safer during loading and parking.
Finish Durability
Powder coating, galvanizing, stainless steel, or custom color should be selected based on indoor/outdoor use, corrosion exposure, and brand requirements.
Export Packing
Assembled, semi-assembled, knock-down, carton, pallet, and spare wheel packing options affect freight volume, assembly time, and after-sales support.
Quality Checks
Inspection Points for This Trolley Type
Quality checks are adjusted according to the actual trolley type, structure, load, and application.
Shelf height and deflection under full load
Fit check against real cartons or totes
Handle height and push clearance check
Aisle turning test at the stated aisle width
Caster rolling and brake holding when loaded
Finish, edge protection and packing check
Angle and squareness checked against a template on every welded frame.
Joint-by-joint angle checks happen during assembly, not only at final inspection.
Same gauge, same angles — that is how unit 500 matches unit 1.
Specifications
Custom Trolley Specification Options
| Item | Options to Confirm |
|---|---|
| Load Capacity | Confirmed from the actual cargo, load distribution, route, floor and safety factor; the quotation should not rely on a generic load class alone |
| Sheet / Tube Thickness | Confirmed from material grade, load path, part geometry and downstream process. Current thickness limits are reviewed against the selected machine and drawing. |
| Material | Carbon steel, stainless steel, aluminum, steel mesh, or combined structure |
| Size | Standard or custom platform, shelf, cage, or drawer dimensions |
| Wheel Type | PU, rubber, nylon, pneumatic, fixed, swivel, brake caster, or heavy-duty caster |
| Structure | Flat platform, shelves, side rails, cage, drawers, foldable handle, knock-down packing |
| Finish | Powder coating, galvanizing, stainless finish, custom color, or other finish as required |
| MOQ / Sample | Standard MOQ is 50 units. For large-size or heavy-duty trolley projects, quantities from 10 units may be discussed. Sample and first-article arrangements are reviewed separately. |
| Lead Time | Quoted after drawing, material, quantity, finish, wheel sourcing and packing are confirmed |
| Packing | Fully assembled, semi-assembled, knock-down, carton, pallet and spare-part options |
| Branding | Logo, label, custom color, private-label packing, and distributor program support |
DFM and Inspection Review
Six Design Risks We Check Before the Trolley Enters Production
A drawing can look complete and still leave the most expensive problems unresolved. Attach your drawing or reference photos and identify these points before quotation.
Caster plate flatness, bolt pattern and wheel clearance
Load path from deck or shelves into the welded frame
Handle height, reach, turning space and operator access
Hole, slot and bend clearance around assembly interfaces
Finish build-up around threads, hinges and moving parts
Assembled or knock-down packing volume and protection
Applications
Where This Trolley Is Used
Piece picking and batch picking
Replenishment routes
Returns processing
Packing bench supply
E-commerce fulfilment
Spare parts and MRO picking
Cold-store and temperature-controlled picking
Related Pages
Continue the Product and Process Review
These links help Google and buyers understand which page owns each topic, while giving your team the supporting process details.
Manufacturing Process
From Structure Review to Export Packing
The production route can include tube cutting, laser cutting, CNC bending, welding, surface treatment, wheel installation, final function checks, and export packaging. For OEM projects, drawings or samples help improve quotation accuracy.
RFQ Details Needed
- Product type, reference photo, or drawing.
- Overall size, platform size, shelf count, or cage dimensions.
- Target load capacity and cargo type.
- Wheel type, brake requirement, and floor condition.
- Material, finish, color, logo, packing, and order quantity.
FAQ
Common Questions Before Ordering Custom Trolleys
How do we choose shelf height and pitch for a picking cart?
Start from your carton or tote range and the reach height your operators work at comfortably, then set pitch from the tallest regular carton plus clearance. Send the carton sizes and we will propose a layout before anything is drawn.
Can the cart be built for a specific aisle width?
Yes. Send the narrowest aisle, turning space at the ends, and how tight the corners are. We then review frame width, handle projection, caster layout and brake reach so the loaded cart can be turned by one operator.
Can you add holders for scanners, printers or tablets?
Yes. Document shelves, scanner or tablet mounts, label printer shelves, bin rails and tote holders can be built in. Send the device model or mounting plate drawing and we will match it.
Can you customize the size?
Yes. Overall size, platform size, shelf layout, cage size, handle height, and wheel configuration can be customized based on your use case.
Can I send a photo instead of a drawing?
Yes. Photos, samples, sketches, and use requirements can start the review. Drawings are recommended for accurate quotation and production.
Which wheel should I choose?
Wheel choice depends on load, floor type, noise requirement, movement distance, brake needs, and whether the trolley is pushed, pulled, or parked on slopes.
Can the trolley be foldable?
Foldable handles, foldable cages, removable shelves, and knock-down packing can be discussed when storage space or freight volume is important.
Do you support OEM branding?
Custom color, logo plate, label, carton artwork, and distributor packing can be reviewed for OEM and private-label trolley programs.
Can it work with towing equipment?
For heavy loads or long routes, please confirm tow bar, coupling arm, forklift, tugger cart, or AGV interface requirements during the RFQ stage.
What is the MOQ?
Our standard MOQ is 50 units for most custom trolley programs. For large-size or heavy-duty projects, quantities from 10 units may be discussed after reviewing the structure, material, casters, finish and packing. Samples and first articles are handled separately.
Can you quote from a PDF, DWG, DXF or STEP file?
Yes. Those formats are accepted for review, and reference photos or samples are useful when the drawing does not show the working environment.
How is lead time confirmed?
Lead time is confirmed after the drawing revision, material, quantity, finish, wheel model and packing method are agreed. We avoid giving a generic date that does not fit the project.
Can you provide supplier approval documents?
Tell us which documents your purchasing team needs. Material, inspection, packing and project records can be discussed, while certifications are published only after internal verification.
How will the trolley be packed?
We can review assembled, semi-assembled or knock-down packing, including cartons, pallets, hardware bags, labels and finish protection according to the shipping plan.
Can I request a sample or first article?
Yes. Sample or first-article review can be discussed according to the drawing maturity, project quantity, tooling and approval process.
Request a Quote for This Trolley
Send your trolley type, load capacity, size, wheel requirement, quantity, and drawings or reference photos. Our team will review the structure and reply within 24 hours on business days.
Urgent project? Email gao@doingmetal.com or WhatsApp +86 18158549983.
