Warehouse Material Handling Equipment: Pallet Trucks, Stackers and Reach Trucks

When do you need a pallet truck?

Choose a pallet truck when the load mainly needs to travel rather than be lifted into racking. It can move pallets more efficiently and with a smaller footprint than using a counterbalance forklift for every horizontal journey.

Bobcat offers pedestrian pallet trucks for compact routes, including entry-level and BPM16/20N-7 models, and BPR20/25N-7 ride-on pallet trucks for longer routes and sustained travel.

Before choosing a model, check:

• Maximum and typical pallet weight
• Pallet dimensions and required fork length
• Narrowest doorway and turning area
• Route length and busiest-hour movement count
• Floor transitions, ramps, and dock interfaces
• Whether operator walking would limit throughput or increase fatigue

What does a stacker add?

A stacker moves a pallet and raises it into racking. It bridges the gap between a pallet truck and a full forklift or reach truck.

A pedestrian stacker can suit a smaller warehouse with compact routes and moderate rack height. Bobcat entry-level LSM12N-7(i) and BSL12/16N-7(i) models provide this type of handling. BSR12/16N-7(i) ride-on stackers are a stronger fit when the operator travels farther or stacks more frequently; selected configurations offer optional Li-Ion power and an integrated charger.

The deciding question is not only whether the stacker reaches the rack. Confirm that it retains enough capacity at the required height and that its support-leg and pallet configuration fit the load.

Bobcat 9-Series reach trucks are designed for high-rack warehouse work and include stability and visibility features. Selection should be based on:

• Required lift height
• Actual load center and pallet dimensions
• Residual capacity at the working height
• Floor flatness and condition
• Real working aisle, including the pallet and operating clearance
• Operator training and site traffic design

A headline capacity does not prove that the truck can safely place the load at the highest rack level.

Should you choose a pedestrian or ride-on truck?

A pedestrian pallet truck is usually the better starting point for short routes, frequent direction changes, and tight spaces. It takes less room to maneuver and keeps the operator close to the load.

A ride-on truck becomes more attractive when travel distance is longer or the operator spends a large part of the shift moving between zones. It can reduce walking fatigue and support higher throughput, but it requires more turning space and stronger pedestrian controls.

Can one machine cover transport and stacking?

A stacker can cover both tasks when travel distances are moderate, rack height is within its working range, and the tasks do not compete for the machine at the same time.

A mixed fleet is usually stronger when:

• Long transport routes favor a pallet truck
• High racking requires a reach truck
• Dock work requires a counterbalance forklift
• Several tasks occur concurrently
• One breakdown would stop receiving or dispatch

The best fleet is not necessarily the one with the fewest machines. It is the one that avoids expensive equipment doing simple work and prevents one task from blocking another.

What should you test before buying?

Use real pallets in the real layout. Test:

• Entry into the narrowest aisle and doorway
• Turning with the longest regular load
• Lift and placement at the highest regular rack position
• Visibility during travel and stacking
• Cycle time over the actual route
• Operator comfort during representative use
• Charger location and shift-handover process

A demonstration under normal working conditions is more useful than choosing from specifications alone.