5 Benefits of electric tugs

Material handling electric tugs

Electric tugs let one operator move heavy wheeled loads safely; cutting manual handling risks, removing reliance on forklift trucks, and running on zero emissions. So more companies are choosing to invest in alternative load moving solutions and unlocking the benefits of using our electric tugs and tows.

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5 benefits of an electric tug
Electric Tug Essentials_Sunbelt Rentals

1. How do electric tugs boost productivity?

An electric tug lets a single operator connect to a wheeled load and move it without having to wait for a licensed forklift driver or needing multiple staff to dedicate time to manually move loads.

With MasterMover electric tugs, a single operator can move up to 300,000kg in challenging or congested industrial environments. So now the staff who used to be tied up in a multi-person move are free to focus on higher-value tasks.

Sunbelt Rentals reduced manpower for trailer moving tasks by 75% with our PowerSteered tugs, also boosting efficiency by 300%.

Electric Tug Essentials Benefits_Manchester Airport [Right]

2. Do electric tugs reduce manual handling?

Rather than a person pushing, pulling, or steering heavy loads by hand, electric tugs take all the strain. Manual handling accounts for 17% of all non-fatal workplace injuries in the UK (HSE, 2024). It's a far bigger safety issue than most businesses realise and is what electric tugs are built to eliminate.

Creating a secure, unbreakable connection to the load, our electric tugs reduce the risk of trapped limbs and toppling loads as well as the repetitive strain that leads to musculoskeletal disorders.

Manchester Airport Group's Motor Transport team reduced lost-time incidents by 100% after switching to our MasterTow electric tugs to move heavy baggage trailers through workshops, also boosting productivity by 200%.

Electric Tug Essentials Benefits_Pharmaceutical [Left]

3. Are electric tugs suitable for tight or congested spaces?

Traditional handling equipment or fixed infrastructure, such as forklifts or overhead cranes, lock you into a fixed layout. MasterMover electric tugs do the opposite; scaling up or down with demand and adapting to changing layouts whilst navigating congested pedestrian sites.

A small turning circle and compact footprint allow electric tugs to work in spaces where forklifts and larger handling equipment can't safely operate, such as narrow aisles, tight corners, and high-footfall areas - ideal for pharmaceutical manufacturing, retail, and logistics environments.

"In terms of safety, what the MasterMover brings is exactly what we wanted to do... it removes the manual handling piece in its entirety and therefore reduces the risk of those musculoskeletal injuries."

Kevin Hainey Head of Motor Transport · Manchester Airport Group

"We have several safety roadmaps, and that's really part of our safety culture for zero harm. As part of that, one of the key things is to try and reduce forklift truck movement and segregate those from our team members."

Rachel Pattison Operations Improvement Manager · Terex
Electric Tug Essentials Benefits_Savings [Right] (1)

4. Do electric tugs save money on handling

Electric tugs save money on three fronts: capital investment, training costs, and maintenance. Fixed equipment like overhead cranes is expensive to move or reconfigure, and maintaining a fleet of forklifts comes with ongoing costs from purchase, servicing, and licensed-operator training.

An electric tug costs a fraction of the price to purchase, requires no operator licence, and has low maintenance requirements - so the savings compound over the life of the machine.

Electric Tug Essentials Benefits_Emissions [Right] (1)

5. Are electric tugs environmentally friendly?

Unlike alternative methods which may run on fuel, there are no harmful diesel fumes with a battery powered electric tug or tow tug. A MasterMover is flexible enough to be used inside and out and, because there are no harmful exhaust gases, no additional ventilation is required.

Low emission, low noise load moving methods are a win-win for everyone. Not only is this good for the environment, it’s great for staff too.

Terex switched to our remote controlled PowerSteered electric tugs to create forklift-free zones in their Materials Processing division, minimising diesel emissions on site. Our customer in Germany was able to cut 11,000kg of CO2 emissions each year from their pre-casting facility by replacing diesel-powered equipment with our electric tugs.

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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. 

FAQs: Your questions, answered

What are the main benefits of an electric tug?

Electric tugs help businesses improve productivity, reduce manual handling, work safely in tight spaces, reduce reliance on larger traditional handling equipment (such as forklift trucks and overhead cranes), and support lower-emission operations. The main advantages come from letting one operator do a job that previously needed several people or licensed equipment, while reducing the physical effort required from operators.

How do electric tugs improve productivity?

An electric tug allows a single operator to move heavy and awkward loads quickly, without waiting for larger equipment and licensed operators, or multiple people to become available. This helps reduce delays and frees up more employees for other value-adding tasks.  

What are the safety benefits of an electric tug?

Yes, electric tugs reduce several sources of workplace risk at once: manual handling injuries from pushing and pulling loads by hand, loss of control on slopes or uneven floors, and the musculoskeletal disorders caused by repetitive strain.  Instead of staff pushing and pulling heavy loads by hand, the machine takes all of the strain. A secure connection to the load helps improve control.

 

Are electric tugs suitable for narrow or congested spaces?

Yes. One of the key advantages of an electric tug is its compact footprint and manoeuvrability. They are well suited to workplaces with corners, narrow aisles, foot traffic, or limited operating space where larger equipment may be less practical. 

Can electric tugs replace forklifts or cranes?

In many wheeled load moving applications, an electric tug can be a practical alternative to forklifts, overhead cranes, or fixed moving systems. The right choice depends on the load, route, floor conditions, and connection method, but electric tugs are often selected where flexibility, compact size and lower training requirements matter most. 

Do electric tugs save money?

Electric tugs can help reduce spending on more expensive moving methods, avoid costly layout changes linked to fixed infrastructure, and lower labour inefficiencies by allowing one operator to move loads safely and efficiently.  

Are electric tugs environmentally friendly?

Battery-powered electric tugs can offer environmental benefits compared with fuel-powered alternatives because they do not produce diesel fumes during operation. They are also well suited to indoor use where low-emission handling methods are important.  

Which industries benefit most from electric tugs?

Electric tugs are used across industrial manufacturing, logistics, retail and healthcare, particularly where businesses need to move heavy wheeled loads more safely and efficiently.  

Why use an electric tug?

Businesses switch to electric tugs when manual handling becomes a safety or productivity bottleneck, or when a forklift is no longer practical and efficient - too large for the space, too costly to run, or reliant on a licensed operator who isn't always available. An electric tug removes all three constraints as it doesn't require a licence, is highly manoeuvrable for threading through tight spaces, and lets one person handle a task that previously took several. Explore why businesses use electric tugs for a deeper analysis.