From Forklifts to AGVs: How Autonomous Vehicles Are Reshaping Material Transport

For decades, forklifts have been the backbone of warehouse material handling. They’re familiar, versatile, and deeply embedded in operations. But in recent years, a new force has been quietly transforming how goods move inside facilities: Autonomous Guided Vehicles (AGVs).

As Canadian manufacturers and logistics operators face rising labour costs, increasing safety expectations, and the need for more predictable operations, many are asking a simple question:👉 Is it time to move from forklifts to AGVs?

The answer, for many, is yes.

The Challenges of Forklift-Based Material Handling

Forklifts are powerful tools, but they also bring a set of challenges that are becoming harder to ignore in today’s environment:

1. Safety Risks

Forklifts are a leading cause of warehouse accidents. In high-traffic areas, the mix of people, pallets, and vehicles can be unpredictable. Even skilled operators face risks from blind corners, fatigue, or uneven floor conditions.

Accidents lead to downtime, injuries, investigations, and insurance costs — all of which eat into productivity and profitability.

2. Labour Dependence and Shortages

Operating forklifts requires certified drivers. Across Canada, many facilities are struggling to recruit and retain enough qualified operators to keep material moving. Labour shortages and rising wages make forklift-heavy operations increasingly expensive and unreliable.

3. Unpredictable Performance

Human-operated forklifts introduce variability into warehouse workflows. Travel speeds, routing decisions, and load handling can differ from operator to operator. This lack of consistency makes it difficult to achieve precise, repeatable processes — something that modern supply chains increasingly demand.

The Shift Toward Autonomous Material Handling

Autonomous Guided Vehicles (AGVs) are purpose-built to move materials safely, predictably, and cost-effectively. Unlike forklifts, AGVs follow predefined routes, use advanced sensors to detect obstacles, and operate around the clock with minimal human intervention.

This shift isn’t about replacing humans entirely — it’s about freeing up skilled workers to focus on higher-value tasks while AGVs handle repetitive transport work efficiently.

Key Advantages of AGVs Over Forklifts

🦺 Improved Safety

AGVs use lidar, cameras, and safety scanners to detect obstacles and stop automatically when needed. This significantly reduces the risk of collisions, injuries, and product damage. They follow consistent paths, eliminating the unpredictable behavior often associated with forklifts.

⏱ Predictable, 24/7 Operation

Once deployed, AGVs run on a consistent schedule, maintaining steady throughput without breaks, fatigue, or variability. This predictability allows facilities to plan with greater accuracy, reduce delays, and optimize workflows end-to-end.

💰 Lower Operating Costs Over Time

While the initial investment in AGVs can be higher than buying a forklift, the total cost of ownership is often lower. AGVs reduce labour costs, energy use, insurance claims, and damage expenses — and they can operate for years with minimal maintenance.

Meet Tusk AGVs: A Practical Solution for Canadian Facilities

At Humphrey Logistics Automation, we partner with Tusk Robotics to bring robust, flexible AGV solutions to Canadian manufacturers and logistics operators.

Tusk AGVs are designed for real-world warehouse conditions — they handle heavy loads, navigate complex routes, and integrate with existing operations seamlessly. Whether you’re transporting pallets across long distances, feeding production lines, or connecting inbound and outbound areas, Tusk AGVs offer a scalable path to automation.

Why Tusk AGVs Stand Out:

• Modular deployment – Start small and scale up as needed.

• Easy integration – Compatible with existing infrastructure and workflows.

• Built for safety – Advanced sensors and navigation ensure reliable operation.

• Local support – Delivered and supported by a Canadian partner who understands your environment.
  

A Smarter Way to Move Materials

The shift from forklifts to AGVs isn’t just a technology upgrade — it’s a strategic move toward safer, more efficient, and future-ready operations.

As labour markets tighten and safety regulations strengthen, early adopters of AGVs are gaining a competitive edge. They’re moving goods more predictably, scaling operations without increasing headcount, and creating safer workplaces for their teams.

👉 Humphrey Logistics Automation can help you explore how Tusk AGVs fit into your facility — from initial design to deployment and support.