How Custom Racks & Carts Improve Workflow in Window Production
In the window manufacturing industry, there’s always pressure to crank things out quicker, but without compromising on quality or safety. Most people focus on the big stuff, like machines, automation, and fancy technology, but one thing that quietly makes a huge difference often gets overlooked: how you handle and move your materials.
From raw stock to finished frames, if the flow’s not smooth, everything else starts to feel like a grind. Slowdowns, damaged parts, safety risks, and whatnot. That’s where custom racks and carts come in. These are built just for your setup, your materials, your sizes, and your pace. At the end of the day, when your materials are easier to move, your whole operation just flows better. It’s one of those “small change, big impact” moves that pays off.
Why Material Handling Matters
In window production, you’re not dealing with small, easy-to-move parts. Most materials, like large glass panes or bulky frames, are heavy and sometimes fragile. Glass needs to be handled with care to avoid chips or cracks, while frames can vary a lot in size and weight, making them tricky to move efficiently.
On top of that, parts in progress need to travel between workstations quickly to keep production flowing. And once everything’s finished, you need a reliable way to store and organize it all without risking damage or clutter.
Improper handling in any of these phases can lead to:
➤ Broken or scratched glass
➤ Bent aluminum frames
➤ Unsafe working conditions
➤ Workflow bottlenecks
➤ High rework and replacement costs
Good handling isn’t just about getting parts from one point to another. It’s about protecting the integrity of your product, keeping employees safe, and ensuring a consistent pace of work.
How Custom Racks and Carts Improve Workflow
Keeping Things Moving on the Floor
In a busy shop, materials are always on the move, coming in, getting cut, glazed, framed, finished, and then shipped out. If that flow slows down, everything backs up. That’s where custom carts earn their keep.
Instead of trying to make standard carts “kind of work,” custom ones are built for your parts, your frame sizes, your glass widths, your workflow.
The result?
➤ Fewer back-and-forth trips
➤ Less heavy lifting for your crew
➤ Easier handoffs between stations
➤ Quicker turnaround without the usual holdups
It’s like giving your shop floor its fast lane; everything just moves better.
Preventing Product Damage
When carts or racks aren’t built for your materials, things can shift, slide, or knock into each other. And with delicate (and pricey) items like IGUs or finished frames, even a small bump can mean a costly crack or scratch.
Custom racks solve that by being built to fit. They can include things like padding, dividers, slots, or tilt angles, whatever it takes to keep your materials safe and steady as they move through the shop.
That means less damage, less waste, and more products leaving the line ready to go, not heading back for rework.
Making the Most of Your Floor Space
Let’s face it, shop floor space is always at a premium. You’ve got machines, people, materials, and parts all needing room to breathe. That’s where smart racks and stackable carts come in.
By going vertical, you free up floor space without losing storage. Suddenly, things aren’t piled up or scattered around; they’re organized, easy to reach, and out of the way.
What does that mean for your team?
➤ Less clutter and fewer trip hazards
➤ Faster access to both in-process and finished parts
➤ A cleaner, more efficient workspace overall
When everything has its place, your crew spends less time finding stuff and more time getting things done.
Boosting Ergonomics and Safety
Handling heavy frames or large glass panels by hand isn’t just inefficient; it increases the risk of injury. Repeated lifting, bending, or carrying awkward items can take a toll on workers over time.
Custom carts are designed to reduce that physical strain. With features like ergonomic handles, secure brake systems, and smooth-rolling casters, materials can be moved easily and safely with minimal lifting required.
This not only lowers the chance of workplace injuries but also helps employees stay focused, comfortable, and productive throughout the day.
Supporting Specialized Tasks
Some carts and racks are tailored to a specific task, like glazing, staging for shipment, or temporary storage between paint and assembly. These dedicated solutions reduce the need to “make do” with the wrong tools.
For example:
➤ A glazing cart can hold several panes at once at the right tilt for safe handling.
➤ A shipping rack can be fitted with feet for secure loading and transport.
➤ A transfer dolly can bridge workstations without constant forklift use.
Custom equipment ensures every task is supported by the right tool, reducing delays, rework, and inefficiency.
When Should You Consider Custom Handling Equipment?
If you’ve experienced any of the following issues, it’s likely time to upgrade your carts and racks:
➤ Broken or scratched products during internal movement
➤ Crowded work areas and cluttered storage
➤ Lost or damaged parts in staging zones
➤ Frequent downtime while waiting for forklifts
➤ Injuries or strain-related complaints from staff
Investing in custom handling systems may seem minor, but it can unlock major gains in throughput, accuracy, and safety.
How Kear Fabrication Delivers Purpose-Built Solutions
At Kear Manufacturing, the Racks & Carts lineup is designed specifically for the window and door industry. Their offerings include:
➤ ‘A’ Type Shop Dollies (K-05AS): Ideal for moving frames or panels securely on the shop floor. Built for frequent daily use.
➤ ‘L’ Type Dollies (K-05LS): Provide a different profile for longer or irregular components.
➤ “A” Frame Slotted Rack (K-06EWE): Keeps parts upright and separated for organized staging and easy access.
➤ A-Type Glazing Racks (K-28BA): Perfect for prepping and storing glass before or after assembly.
➤ A-Type Stackable Racks (K-08AS): Maximize space while organizing finished or semi-finished units.
➤ A-Type Welded Dollies (K-05A): Durable, long-term carts for heavy-duty transport needs.
Each product is built with heavy-gauge steel, industrial casters, and industry-specific dimensions to meet your needs. And because every shop is different, we also offer customization, ensuring the rack or cart fits your floor layout, product sizes, and production flow.
Wrapping Up
At the end of the day, it’s the simple things, like how you move and store your materials, that can make the biggest difference on the shop floor. Custom racks and carts don’t just keep things tidy; they help your team work faster, safer, and with fewer headaches.
Kear’s equipment is built with real production challenges in mind. If you’re dealing with damaged parts, tight spaces, or clunky movement between workstations, it might be time to upgrade. A better workflow really can start with better carts.
FAQs
Do I need custom carts if I already have standard ones?
If your current carts are doing the job without issues, great. But if you're constantly adjusting, modifying, or just "making it work," that's a red flag. Custom carts are designed for your specific materials and processes, which means less damage, fewer delays, and a smoother flow on the shop floor.
How can racks and carts help reduce product damage?
Most damage happens when parts shift, slide, or get knocked around during handling. Custom racks are designed to fit your materials snugly, often with padding, dividers, or angled slots to keep things stable. That means less risk of scratched frames or cracked glass during internal movement.
What makes Kear’s racks and carts different from others on the market?
Kear builds their products specifically for the window and door industry. That means every rack or dolly is designed with real production challenges in mind, whether it’s frame dimensions, glass handling, or tight workflow layouts. Plus, they offer customization, so your carts fit your operation like a glove.
