Choose Castors For More Than Just The Load Weight

At Wheelco, we work with businesses across New Zealand every day to help them find the right castors and materials handling solutions. One of the most important - and often overlooked - parts of this process is properly testing and understanding your load requirements.

Choosing the wrong castor for your application can lead to downtime, safety risks, or increased maintenance. To avoid these problems, we encourage all customers to carefully test and consider their load types, surfaces, and handling needs before selecting wheels or castors.

Why Different Applications Need Different Solutions

It is a common misconception that one type of wheel or tread will suit all environments. In reality, different workplaces, industries, and even different areas within a site can have very different handling requirements.

Key factors that affect your castor choice include:

• The type of ground or surface the equipment will move across

• The regularity and consistency of the surface

• The frequency and method of loading and unloading

• The typical and maximum weight of loads

• How the application will be moved - i.e. human vs mechanised

• The environment the wheel will encounter

For example, a loading bay designed for forklifts and pallet jacks will have a flat, even surface, while a construction site may present rough, uneven terrain. A solution that works well in a logistics warehouse may struggle on a gravel driveway at a building site.

At Wheelco, we supply a wide range of industries across New Zealand, including:

• Transport and logistics companies

• Supermarkets and distribution centres

• Warehouses and freight facilities

• Trucking and fleet operations

• Factories and manufacturers

• Construction sites

• Bakeries

• Food processing plants

• Educational facilities

• Entertainment venues

Each sector has different demands, and so the wheels and castors used must be selected accordingly.

Load Capacity: It's Not Just About the Total Weight

When selecting castors, it is critical to go beyond simply looking at the total load weight. Real-world use often places additional stress on individual wheels that a basic calculation might overlook.

You need to consider:

• Uneven loading: When a load is first placed on a trolley or cart, it often shifts suddenly or applies more pressure to one side.

• Dynamic weight: As the load moves, bumps, turns, and inclines can temporarily increase the force on one or two castors.

• Point loading: Machinery like forklifts and pallet jacks do not always lower loads evenly onto all wheels.

• Impact loading: It’s unavoidable in a busy work environment to remove any sudden impacts entirely on your handling equipment. That’s why your castors should be up to more than just the resting weight but take quick force easily and keep rolling - safe and stable. 

Because of these factors, we recommend that you choose castors rated for at least 25% the individual weight you expect on each wheel.

For example, if your total load is 400 kg and your trolley uses four wheels, you might assume 100 kg per wheel. However, in reality, one wheel could temporarily bear up to 200 kg or more during loading or uneven movement. Choosing castors rated for these dynamic forces is crucial for long-term reliability.

How Wheelco Helps New Zealand Businesses Get It Right

Selecting the right castors can be complex, which is why Wheelco's team works closely with businesses to find the best solution for their needs.

When you contact us, we will typically ask questions such as:

• What is the total weight of your typical and heaviest loads?

• How are loads transferred onto and off your handling equipment?

• What surfaces will the castors be used on daily?

• Is the movement environment indoors, outdoors, or mixed?

• Will loads be stationary for long periods?

• How often will the equipment be used?

Based on your answers, our team can make an expert recommendation on:

• The correct castor type and materials

• Suitable tread types (e.g., rubber, polyurethane, nylon)

• Weight capacity specifications

• Shock absorption requirements

• Fixtures and fittings needed for your application

We are proud to supply high-quality solutions, including German-engineered Blickle castors, known for their durability and long lifespan. Our products are designed not just to perform today, but to stand up to the daily rigours of New Zealand’s busy commercial and industrial environments.

Common Load Handling Challenges to Consider

When selecting castors and designing a handling solution, remember to think about the small but important challenges that can affect performance:

• Loading and unloading impacts: Forklifts and cranes can sometimes drop or unevenly place loads, creating a sudden shift in weight.

• Inclines and ramps: Moving up or down slopes changes the weight distribution across wheels.

• Rough or uneven surfaces: These cause vibration and sudden shocks that weaker wheels cannot withstand. Lips and drops on the floor may seem minor but can be subtly the most harsh on castors’ longevity if they’re not up to the task - another reason to buy quality only. 

• Heavy-duty daily use: Castors must cope with frequent starting, stopping, and turning under full load without premature wear.

Handling solutions should not need delicate treatment to perform well. In real-world workplaces, they must be robust enough to deal with occasional rough handling and still perform reliably every day.

Visit Us in Tauriko or Get Advice Remotely

Wheelco is based in Tauriko, Tauranga, and we welcome customers to visit our showroom to see and feel different handling solutions in person. You can inspect various castors, wheels, and full trolleys to get a better idea of what might work for your specific application.

However, if you are elsewhere in New Zealand, do not worry - we are more than happy to assist you remotely. Our team can work with you over the phone or email, providing advice, drawings, specifications, and even full handling solutions delivered to your site.

Custom-Built Solutions Available

If you require a fully built handling solution - not just the castors themselves - Wheelco can help. We can work with your specifications, including CAD files, sketches, or descriptions, and build a complete trolley, cart, or handling unit designed for your exact needs.

Our custom builds ensure:

• Correct weight ratings

• Reliable and durable construction

• Fit-for-purpose design for your environment and use case

Whether you are transporting heavy machinery across a factory, moving produce in a warehouse, or handling pallets at a construction site, we can deliver a solution built to withstand whatever you throw at it.

Get in Touch

At Wheelco, we believe that choosing the right castors is about more than just ticking boxes. It is about ensuring your workplace runs smoothly, safely, and efficiently.

If you have any questions, or you would like to discuss your handling needs, contact the team at wheelco.co.nz today, or call us for a friendly chat. We are passionate about helping New Zealand businesses move better - and we would love to help you too.