Why do businesses use electric tugs?

Material handling electric tugs

Businesses use electric tugs to cut manual handling injuries and keep production moving without bottlenecks. A single operator can move loads from 300kg to 300,000kg with no licence needed.

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What does an electric tug do for a business?

MasterMover electric tugs allow a single operator to move heavy, wheeled loads weighing anything from 300kg to 300,000kg. Traditional handling equipment would typically require a crew of licensed drivers and spotters; electric tugs remove these bottlenecks by freeing up teams to focus on the work that matters.

At Manchester Airport Group, a single TOW300 replaced a 3-person manual handling process with a 200% productivity increase and zero lost-time incidents since. At Sunbelt Rentals, a PS800+ LH tug boosted efficiency by 300%.

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What problems do electric tugs solve for businesses?

Electric tugs solve three costly problems: injuries from pushing and pulling heavy loads; production delays while staff wait for a forklift or crane; and skilled labour tied up moving assets instead of making them. Removing these bottlenecks keeps work-in-progress flowing and boosts throughput.

Eliminate manual handling Protect staff from strains & MSD risk by removing manual pushing/pulling processes
Reduce bottlenecks No more time spent waiting for a licensed forklift driver that stalls the line and WIP
Utilise skilled labour Free technicians up from pushing trolleys or equipment to focus on higher value work
More flexible layouts Maximise site layout flexibility without the need for fixed handling systems

The business case for electric tugs

The business case rests on four numbers: lost-time injuries, labour hours per load move, production uptime, and capital cost. Electric tugs cut the first three by removing manual pushing and forkllift dependency, and keep the fourth low because they need no fixed infrastructure or operator certification and retraining.

Metric With MasterMover electric tugs Evidence
Lost-time injury (LTI) rate Removes manual push/pull and keeps vehicles out of pedestrian zones 100% reduction in LTIs at Manchester Airport Group
Labour cost per move Turns 3-4 person handling processes into single-operator tasks 75% of the handling team redeployed at Sunbelt Rentals and 66.7% manpower reduction at Manchester Airport Group
OEE: Performance Faster, repeatable WIP movement between stations 200% productivity increase at Manchester Airport Group and 20% less handling time at Tresse Métallique
Capital cost & flexibility No installation or fixed infrastructure and adapts to any layout changes 50% drop in overhead crane use at Hayward Tyler

Do electric tug operators need a licence?

Operators do not need a special driving licence or hours of training to learn how to use an electric tug.

It’s simple to use, easy to handle and removes the effort out of moving heavy and awkward wheeled loads.

Instead, the electric tug does all the hard work so all a single pedestrian user needs to do is securely attach to the load and guide it where it needs to go.

Tresse Métallique SmartMover SM100 Trolley

Are electric tugs a cost-effective alternative?

Unlike fixed infrastructure such as overhead cranes or a system of pulleys and chains, a MasterMover machine is a cheaper alternative to more costly moving methods. It’s flexible too. If, for example, a production layout changes, then a MasterMover can be easily incorporated into the new workflow, without the need for expensive factory alterations.

What’s more, because of the compact footprint of the machines, an electric tug is ideal for navigating corners and narrow, congested spaces.

Plus, there’s the time and cost savings relating to training. Whereas forklift truck operators need a special license to work in the UK, any member of staff can use an electric tug with just a small amount of training.

That means if something needs to be moved, then there’s no wasted time or waiting around for a trained forklift truck operator to become available. Downtime becomes a thing of the past.

 

Electric tug benefits for businesses & staff

Businesses that use electric tugs can achieve huge gains in efficiency and productivity. A MasterMover electric tug also improves safety for employees. By reducing or eliminating manual handling completely, staff members no longer need to push and pull heavy loads as the machine takes the strain.

There is less risk of accidents, runaway loads, and long-term health problems such as musculoskeletal disorders.

Which businesses use electric tugs?

MasterMover electric tugs are used by every industry and are found in businesses across the globe.

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Manufacturing & assembly

Electric tugs help industrial manufacturers to cut downtime, improve safety for staff, and boost productivity by reducing production bottlenecks.

AllTerrain ATP400 moving nested roll cages

Retail & logistics

3PL logistics providers and retail sectors use electric tugs to boost operational efficiency, making it easier for a single operator to safely move even more to meet increasing customer and seasonal demand.

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Facilities & waste management

From facilities and waste management, to airports and healthcare - our electric tugs are used to maximise operational efficiency and protect staff.

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Specialist environments

Our ATEX compliant tugs are ideal for use in potentially explosive environments, as well as our stainless steel tugs for the food industries and biopharma sectors.

Why choose an electric tug?

Electric tugs offer a wide range of benefits to businesses and operators, which include:

Improving operational efficiency - icon

Improve efficiency and productivity

Eliminate manual handling - icon

Reduces manual handling

Maintenance - icon

No downtime waiting for other machinery

Manoeuvrability - icon

Provide control and manoeuvrability

No hidden costs - icon

A cost-effective alternative to other solutions

Staff safety - icon

Boost safety through busy and congested workplaces

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. 

FAQs: Your questions, answered

Why do businesses use electric tugs?

Businesses use electric tugs to cut manual handling injuries, free skilled staff from moving loads, and keep production flowing without waiting for a forklift or crane - allowing a single operator to move wheeled loads from 300kg to 300,000kg.

Do you need a licence to use an electric tug?

 In general, operators do not need a special driving licence to use an electric tug. That makes electric tugs accessible to more members of staff and reduces the delays associated with waiting for licensed vehicle operators.  

Are electric tugs cost-effective for businesses?

Yes, particularly where businesses want a flexible alternative to fixed infrastructure or want to reduce dependency on more costly moving methods. Electric tugs can be integrated into changing production layouts without the same level of disruption or factory alteration.

How do electric tugs help reduce downtime?

 Because they are simple to use and do not usually require a licence to operate, more team members can move loads when needed, reducing waiting time and keeping workflows moving.  

Are electric tugs safer for employees?

Electric tugs help improve safety by reducing or eliminating the need for staff to push or pull heavy loads manually. The machine takes the effort, helping reduce physical strain and fatigue, as well as supporting better control during movement.  

What types of loads can be moved with an electric tug?

 Electric tugs are typically used to move heavy, awkward, or high-value wheeled loads, including sub-assemblies or work-in-progress (WIP), industrial trolleys, and equipment that would otherwise be difficult or unsafe to move manually.  

Why choose an electric tug over a forklift for some tasks?

 For many applications, electric tugs offer a more compact, pedestrian-operated solution that is easier to deploy in tight spaces and may require less training. They can be especially useful where businesses need precise control around corners or in congested areas.  

Which business environments are electric tugs best suited to?

 They are well suited to manufacturing, logistics and other workplaces where businesses need to move heavy wheeled loads frequently, safely and efficiently in live operational environments.  

What is the business case for electric tugs?

Electric tugs reduce lost-time incidents & manual handling risk, cut the number of staff needed per load move, and remove production bottlenecks waiting for forklift or crane availability. MasterMover customers have reported 200% productivity gains.

How do electric tugs improve productivity?

Electric tugs can turn 3-4 person load moving tasks into a single operator task, allowing any team member to move loads when needed without requiring a licence.

What is a forklift alternative for warehouses?

For moving wheeled loads such as loaded or nested roll cages, trolleys, and trailers a pedestrian-operated electric tug or tow tug is a common forklift alternative. With a compact footprint that works at walking pace, it needs no licence to operate and comes with built-in safety features to maximise uptime and safety.