Pallet trucks and stackers: The overlooked workhorses of warehousing

Criterion Equipment specialists take a look at the crucial role of pallet handling machines used to enhance forklift trucks in logistics.

“While forklifts tend to draw the most attention in warehousing and logistics, smaller pallet handling equipment is often the backbone of daily operations, providing cost-effective, reliable performance where space and budgets are constrained,” explains Brenton Kemp, managing director of Criterion Equipment, exclusive distributors of TCM forklift trucks in Southern Africa. “Although forklifts play a crucial role in materials handling and logistics, pallet trucks and stackers provide the flexibility and precision needed in everyday warehousing tasks.

“Our team works closely with customers in all sectors to support compliance and operational efficiency, by matching the correct machine for the specific task. Choosing the right machine for load weight, lift height, aisle width and hygiene requirements, improves productivity and reduces downtime, while ensuring compliance with safety standards.

“An example of how pallet handling machines enhance the efficiencies of forklift trucks can be seen at one of our customer’s distribution centres. At this mid-sized distribution facility – which handles both bulk goods and smaller packaged items – forklifts are used for loading bays and heavy lifting. Electric pallet trucks move goods between staging areas, while high-lift pallet trucks support packing stations by raising loads to waist height. Pedestrian stackers in the facility replenish stock quickly in narrow aisles, without disrupting larger equipment. The efficient combination of equipment improves throughput and creates safer working conditions, without the need for additional forklifts.”

Manual hand pallet trucks remain the most common tool for short-distance horizontal movement of palletised goods. These robust machines – typically rated for loads between 2 000 kg and 2 500 kg – are valued for simplicity, durability and low operating costs. In facilities with frequent load movement, electric pallet trucks deliver higher productivity by reducing manual effort. Compact models can handle up to 3 000 kg and are particularly effective in large warehouses or distribution centres where operators travel long distances.

Pallet stackers add vertical lifting capability, enabling operators to stack goods to heights of 1.6 m to 5.5 m, depending on the model. Manual stackers suit lighter loads up to 1 000 kg, while semi-electric stackers combine powered lifting with manual travel, for a balance of affordability and efficiency. Fully electric stackers, designed for intensive use, handle up to 2 000 kg and are well suited to medium-lift racking applications, where speed and operator comfort are priorities.

High-lift pallet trucks are frequently overlooked despite their importance in improving safety and ergonomics. These machines, with lift heights up to 800 mm, allow pallets to be raised to a convenient working level, reducing bending and strain during picking, packing and assembly. Pedestrian stackers, designed for operation in aisles as narrow as 2.5 m, provide the manoeuvrability required for restocking, order picking and feeding production lines where space is limited.

Specialised pallet trucks address niche applications. Low-profile designs handle pallets with reduced ground clearance, while wide-fork models are used for oversized loads. In industries requiring strict hygiene control, like food processing and cold storage, Stainless Steel pallet trucks provide corrosion resistance and can be cleaned easily to meet stringent sanitary standards.

Criterion Equipment supplies and supports a wide range of TCM pallet trucks and pallet stackers designed for efficient handling, lifting and storage of goods in warehousing and logistics.

The company’s comprehensive range of TCM equipment comprises all models of forklift trucks, covering most forklift classes. These include Internal Combustion (IC) counter-balance trucks, electric counter-balance trucks, reach trucks, powered pallet trucks and rough terrain forklifts. Mast configurations vary from standard two stage 3 m masts to high-reach three stage masts.

The Criterion Equipment team offers a technical advisory, spare parts, repair and maintenance service throughout Southern Africa, to ensure optimum performance from every machine.