Many people have only one criterion when choosing casters: whether they can support enough weight.

However, in real-world operating conditions, problems with casters often stem not from “insufficient load-bearing capacity,” but rather from—environmental mismatches, structural incompatibilities, unfriendly floor surfaces, and bearing-related shortcomings. The result? The caster simply won’t move, gets stuck, makes unusual noises, sheds debris, scratches the floor, or even requires frequent replacements, disrupting production rhythms.

Let’s start with a typical case study, and then break down caster selection into “5 core dimensions” for easier implementation.

I. Why are casters often underestimated? A real-life scenario where they’ve been “unable to move” for three months.

We recently worked with a food-processing company that had just purchased a batch of stainless steel hand trucks. After only three months of use, the trucks began to show noticeable sticking and increased resistance—workers reported that “the harder they pushed, the heavier they felt.” Even worse, black scratches started appearing on the workshop floor.

The person in charge is very confused:

“Each wheel is rated for 250 kg, yet the entire vehicle weighs only 500 kg—surely the total load capacity is sufficient. So why are there still problems?”

After on-site investigation, the cause turned out to be not complicated but highly typical:

1) Material mismatch with operating conditions

The workshop has been consistently damp, frequently subjected to high-pressure washing, and exposed to mildly corrosive cleaning agents. To cut costs, the customer opted for standard nylon wheels. While nylon is indeed wear-resistant in dry environments, under prolonged exposure to moisture it can absorb water and swell, increasing the risk of rusting on metal components and bearings. This ultimately leads to sluggish rotation or even “stiffness and jamming.”

2) The caster structure does not match the intended usage motion.

The handcart requires smooth, high-frequency turns and effortless steering—but despite opting for a “universal swivel with brake,” the quality and configuration of the bearings and steering mechanism fall short. Under heavy loads, wear accelerates rapidly, and rotational resistance rises sharply—while the cart can handle the weight, its handling performance has completely deteriorated.

3) Ground protection was overlooked.

The wheel surface is relatively hard and contains many impurities, making it prone to leaving stubborn scratches and dark marks on delicate surfaces such as epoxy resin floors.

The renovation plan is straightforward: replace the wheel surface material with one more suitable for food-processing conditions (such as TPU or polyurethane), adopt a more reliable bearing configuration, and upgrade the bracket material to corrosion-resistant or stainless steel. Once these changes are made, the problem will immediately be alleviated.

What this case aims to illustrate is:

Load-bearing capacity is merely the threshold for determining whether something “can be used”; when selecting a product, the key considerations are whether it’s “easy to use, how long it will last, and whether it might cause additional losses.”

II. The 5 Core Dimensions for Caster Selection (From “Functional” to “User-Friendly”)

Dimension 1: Environmental Adaptability in Use (First consider the environment, then select materials)

Casters are most vulnerable to “environmental mismatches.” Common scenarios have completely different material requirements:

High-temperature environments (such as baking ovens and around boilers): Ordinary rubber tends to soften and deform easily; therefore, it’s necessary to consider high-temperature-resistant materials (such as high-temperature nylon, cast iron, etc., selected based on the specific operating conditions).

Low-temperature cold storage: Some materials become brittle and crack; therefore, wheels with low-temperature-resistant formulations or compatible materials should be selected.

Humid/Washing/Weak Corrosion (Food Processing, Slaughtering, Central Kitchens): For supports, stainless steel or corrosion-resistant treatment is preferred; for bearings, a waterproof, dustproof, and sealed design is highly recommended.

Cleanroom/Electronics/Pharmaceuticals: Requirements include antistatic properties, low outgassing, resistance to dust accumulation, and even specific demands regarding material odor and powder shedding.

In a nutshell: If you clearly define “temperature, humidity, chemical media, and cleaning methods,” you’ll already be halfway to successfully selecting the right casters.

Dimension 2: Ground Matching and Protection (The ground is an asset; the casters need to be “friendly”)

Nowadays, the cost of flooring in many factories and shopping malls is quite high, and the repair costs caused by damage from caster scratches often exceed the cost of the casters themselves.

Epoxy, tiles, wood flooring, and marble: It’s recommended to choose wheel surfaces that are “softer, more resilient, and cleaner,” such as PU, TPU, TPE, or rubber, to reduce the risk of black marks and scratches.

Rough cement, asphalt, and outdoor surfaces: These surfaces place greater emphasis on wear resistance and cut resistance, requiring wheel surfaces and structures that are more durable and tougher.

A common misconception:

The harder the wheel, the less effort it takes?

Not necessarily. On rough surfaces, hard wheels tend to be bumpier, noisier, and subject to greater impact, making them more likely to damage bearings and brackets.

Dimension 3: Flexibility and Handling (“Easy to Push” – Focus on Bearings and Steering Mechanism)

For many vehicles that “won’t move,” the problem lies not in the wheel surface itself, but rather in the bearings and steering.

The bearing selection differs for light and heavy loads.

Lubrication and protection requirements differ between high-speed and low-speed applications.

The machining accuracy of the steering structure directly affects whether the 360° rotation is smooth.

To achieve “lightness and smooth turning,” it’s not just about the wheels—much more importantly, you need to look at:

Bearing type, sealing rating, steering wheel structure, and machining accuracy.

Dimension 4: Safety (Brakes are not decoration—they’re part of the system)

Wheelchair safety is often simplified to “as long as there’s a brake,” but in reality, there are many nuanced considerations:

Side brake/Forward brake: Common basic braking.

Dual Brake: Simultaneously locks both rolling and steering, ideal for scenarios with high stability requirements.

Ramp/Slope Conditions: Enhanced parking capability or special braking solutions may be required to prevent skidding accidents.

If there are personnel operating on the equipment, precision instruments are involved, the terrain is sloped, or frequent stops and starts occur, safety priority must be heightened.

Dimension 5: Dynamic Performance (Impact Resistance, Fatigue Life, and Maintenance Costs)

Casters aren't designed for static loads; instead, they face dynamic loads caused by continuous pushing, turning impacts, and uneven surfaces.

So, beyond “nominal load capacity,” what’s even more critical is:

Dynamic load capacity

Impact resistance

Fatigue life (structural stability after long-term rolling)

Dust and water resistance, plus ease of maintenance (can we reduce the need for frequent maintenance and downtime?).

Many companies frequently change wheels—when you factor it all in, it’s not the wheels themselves that are expensive, but rather the downtime, labor costs, and rework expenses.

III. From “Selling Casters” to “Developing Solutions”: Solving Problems from the Perspective of Application Scenarios

In the caster industry, what truly matters isn't memorizing specification sheets—it's being able to ask the right questions.

What is the surface material? What is its roughness?

Humidity, cleaning method, and whether chemical media are involved?

Total equipment weight versus single-wheel distribution—Is there any uneven loading?

Deployment frequency, turning radius, speed, and whether silence is required?

Do you need antistatic, traceless, and cleanroom-grade?

Only by clarifying these scene parameters can the caster selection move from “close enough” to “just right.”

IV. Conclusion: Load-bearing capacity is only the starting point; true selection lies in “system matching.”

Back to the original question: When choosing casters, is it enough to just check whether the load capacity is sufficient?

Of course, it’s not enough.

Load-bearing capacity determines “whether it can hold up,” but the following 5 dimensions determine “whether it can remain functional and reliable over the long term”:

Environmental adaptation

Ground matching

Control and Flexibility

Safety brake

Dynamic Life and Impact Resistance

When you treat casters as the “legs” of your equipment—rather than just “accessories”—you’re not just selecting a wheel; you’re opting for greater mobility stability and lower overall costs.