Custom Modular and Lean Trolleys Built for Your Exact Needs
Off-the-shelf trolleys will do a passable job, but they never quite fit your operation properly. Our modular tube and joint systems let you build trolleys configured exactly for your loads, workspace, and workflow requirements, saving you time, staff hours, and money.
The Problem With Standard Warehouse Picking Trolleys
Generic trolleys often cause operational issues:
- Wrong size for your products or workspace
- Poor ergonomics leading to worker strain and injuries
- Can't be modified when requirements change
- Don't integrate with existing equipment or processes
- One-size-fits-all approach that fits nobody perfectly
Custom-built modular trolleys solve these problems by being designed around your specific needs.
Engineered Performance for Every Picking Route
Our modular picking trolleys are built around a strong tube‑and‑joint frame with plastic coated steel or stainless options, a variety of wear surfaces can be specified and we utilise industrial castors designed for smooth, stable movement across warehouse routes.
Load capacities range can range from 100 kg to 500 kg+, with multi‑tier, tote‑compatible and angled‑shelf configurations that adapt to varied SKU sizes and picking workflows.
Adjustable shelves, secure tote rails, ergonomic handles and optional ladder integration support safe, efficient picking in manufacturing, e‑commerce and distribution environments, while accessories such as scanner mounts, document holders and tool trays allow each trolley to be configured for specific operational needs.
How Modular Trolley Systems Are Superior
We use precision-engineered stainless steel tubes and joints to build trolley frameworks configured exactly for your requirements. Add multi‑tier shelves, bins for order picking trolleys, handles, and accessories like steps or ladders precisely where you need them.
No welding or specialist fabrication required - just robust, professional trolleys assembled with basic tools and modified easily when your needs change.
Common Trolley Configurations
Our modular picking trolley systems are designed to support warehouse fulfilment, manufacturing, assembly operations and line-side replenishment.
Popular configurations include multi-tier picking trolleys for order fulfilment, kitting trolleys for delivering components to production lines, tote-compatible trolleys for efficient small-parts handling, ladder picking trolleys for high-bay warehouse operations and heavy-duty material handling trolleys for transporting larger loads.
Every trolley is built around your workflow, helping to reduce travel time, improve picking accuracy and support lean manufacturing principles.
Each design can be customised with adjustable shelving, tote locations, scanner mounts, document holders, industrial castors, visual management features and ergonomic handling points.
As processes evolve, the modular tube-and-joint construction allows trolleys to be reconfigured rather than replaced, providing a flexible and cost-effective solution for continuous improvement initiatives.
Multi‑tier trolleys with different shelf heights accommodate varied product sizes within the same trolley. Maximise capacity whilst maintaining organisation.
Order picking trolleys with organised storage for small parts, components, or supplies. These trolleys make for easy loading and unloading with clear visual management.
Our team can create bespoke designs that are compatible with tugger trains or any other warehouse management systems you may already have in place.
Simple, flat, robust platforms for larger items or flexible loading. Add sides, handles, or accessories to the trolley if and when you need them.
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Final Product
Kitting Trolleys for Lean Manufacturing and Line-Side Replenishment
Kitting trolleys play a vital role in lean manufacturing environments by ensuring the right components are delivered to the right place at the right time.
Our modular kitting trolleys are designed to support line-side replenishment and ssembly operations , helping to reduce wasted motion, improve material availability and streamline workflow.
Each trolley can be configured with tote locations, picking bins, visual management features, document holders and customised shelf layouts to suit your products and processes.
As requirements change, the modular tube-and-joint framework can be easily adapted without the cost of replacing the entire trolley, providing a flexible solution for manufacturers focused on continuous improvement and operational efficiency.
Ready to Build Better Trolleys?
If you're dealing with ergonomic issues, trolleys that don't quite fit your operation, or material handling challenges that off-the-shelf solutions can't solve, custom modular picking trolleys might be exactly what you need.
We can assess your current situation and show you how custom-built trolleys could improve your operation. Book a no-obligation call today and receive practical advice and tailored solutions from a team of experts who understand material handling challenges.
Reach out today to book a call.
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Complete Lean Tube
sales@completeleantube.co.uk t: 01949 358 758
Operating Hours: Mon to Fri 9am-5pm
Unit 6, Barbrey Business Park, Orston Lane, Bottesford, Nottingham, NG13 0GY
