Automated Tugger Trains

7 Transformative Applications of Automated Tugger Trains in Material Flow

In today’s fast-paced logistics landscape, efficiency and accuracy are paramount. Warehouse managers are constantly seeking innovative solutions to optimize workflows, reduce costs, and enhance productivity. Automated Tugger Trains, a type of automated guided vehicle (AGV) system, have emerged as a game-changer in this regard, offering a powerful and versatile solution for streamlining material handling operations.

In this blog post, Novus Hi-Tech will delve into the intricacies of Automated Tugger Trains, exploring their functionality, benefits, and their impact on modern warehouse and manufacturing processes.

What are Tugger Trains?

Tugger Trains, also known as tow tractors or tugger carts, are a form of material handling equipment designed to transport multiple carts or containers within a facility. Unlike traditional forklifts or manual transport methods, Tugger Trains operate on a towline system, where a single powered tugger pulls a train of connected carts or trailers. This configuration allows for efficient and organized movement of materials throughout a facility. Tugger trains are essentially  hitched together and guided by a tow tractor, typically an AGV. These AGVs are equipped with sensors and navigation systems that enable them to move autonomously through the warehouse, following predetermined paths and stopping at designated stations to pick up or drop off loads.

Key Features and Components:

1. Tugger Unit:

  • The central component of the Tugger Train is the tugger unit, typically an electric-powered vehicle with a tow hitch or coupling mechanism.
  • These units are designed for maneuverability and ease of use in confined spaces.

2. Carts or Trailers:

  • Attached to the tugger unit are a series of carts or trailers, each capable of carrying specific types of materials or goods.
  • The number and configuration of carts can be customized based on the specific needs of the operation.

3. Towline System:

  • Tugger Trains operate on a towline system, where a physical or virtual guidepath is established for the tugger unit to follow.
  • This system ensures a predefined and efficient route for material transport.

Benefits of Using Automated Tugger Trains: 

  • Enhanced Efficiency: Tugger trains significantly improve throughput by automating repetitive tasks such as transporting materials between workstations. This frees up valuable human labor for more complex tasks, ultimately boosting overall productivity.
  • Reduced Costs: By streamlining operations and minimizing manual labor, tugger trains can lead to significant cost savings. Additionally, their fuel efficiency compared to traditional forklifts contributes to lower operational expenses.
  • Improved Safety: Tugger trains operate autonomously, eliminating the risk of human error and forklift-related accidents, thereby enhancing safety in the warehouse environment.
  • Increased Scalability: Tugger train systems are highly scalable and can be easily adapted to accommodate changing needs or warehouse layouts. Additional carts or trailers can be added to the train as required, ensuring flexibility for future growth.
  • Flexibility and Customization: The modular nature of Tugger Trains allows businesses to customize the configuration of carts based on their unique needs.This adaptability is particularly beneficial in environments with varying material handling requirements.
  • Reduced Labor Costs: Tugger trains can help reduce labor costs by automating material handling tasks, which can be physically demanding and repetitive.

Applications of Automated Tugger Trains in various industries:

Tugger trains find application in various industries and environments where efficient material handling, streamlined logistics, and increased productivity are paramount. Here are some key applications of tugger trains:

1. Manufacturing Facilities:

  • Tugger trains are widely used in manufacturing plants to transport raw materials, work-in-progress components, and finished goods between different production areas.
  • They facilitate just-in-time (JIT) manufacturing by ensuring a continuous flow of materials to the production line, reducing inventory levels and associated costs.

2. Warehousing and Distribution Centers:

  • In large warehouses and distribution centers, tugger trains play a crucial role in moving goods from storage areas to packing stations and shipping docks.
  • They enable batch picking and transportation of multiple items simultaneously, optimizing order fulfillment processes.

3. Automotive Industry:

  • Tugger trains are extensively utilized in the automotive industry to transport components and subassemblies between different stages of the assembly line.
  • Their ability to handle varying load sizes and configurations makes them ideal for the diverse needs of automotive manufacturing.

3. E-commerce and Order Fulfillment:

  • Tugger trains are employed in e-commerce fulfillment centers to streamline the movement of products from receiving areas to order picking stations and eventually to shipping zones.
  • The efficiency of tugger trains is particularly beneficial in handling the high volume of orders characteristic of e-commerce operations.

4. Food and Beverage Industry:

  • Tugger trains are utilized in food processing and beverage production facilities for the movement of ingredients, packaging materials, and finished products.
  • Their design allows for easy integration with hygiene and safety standards common in the food industry.

5. Pharmaceutical and Healthcare Facilities:

  • In pharmaceutical manufacturing and distribution, tugger trains assist in the efficient transport of materials such as raw ingredients, packaging materials, and pharmaceutical products.
  • They contribute to maintaining a well-organized and compliant workflow in environments with stringent quality control requirements.

6. Retail and Supermarkets:

  • Tugger trains are employed in retail settings and supermarkets for restocking shelves and transporting goods from storage areas to the sales floor.
  • The flexibility to customize cart configurations allows for efficient handling of various products.

7. Textile and Apparel Industry:

  • Tugger trains are used in textile and apparel manufacturing facilities for the movement of fabric rolls, garment components, and finished products between different production stages.
  • Their adaptability to handle different types of carts makes them suitable for the diverse needs of the textile industry.


Tugger trains offer a compelling solution for modern warehouse operations, providing a unique blend of efficiency, safety, scalability, and cost-effectiveness. As the demand for automation in logistics continues to rise, tugger trains are poised to play an increasingly vital role in optimizing warehouse workflows and driving business success.

If you’re interested in a live demo of automated guided vehicles or automated tugger trains, our factory automation experts can schedule a visit to our facility. Talk to us now.


Do you have questions about Tugger Trains? If so, please get in touch and our expert team will be glad to help. Or if you are just starting your manufacturing journey, Check out our free ebook on Autonomous Mobile Robots.