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What type of forklift do I need? Counterbalance, reach truck, stacker or pallet truck

What type of forklift do I need? For most warehouses, factories and yards the answer is usually one of four machines: a counterbalance forklift, a reach truck, an electric stacker or a pallet truck. Sites with dense, high racking may also look at very narrow aisle (VNA) trucks. The right one depends on your site: aisle width, lift height, load weight, floor, outdoor work, loading bays and how long the truck works each day. This guide covers each in turn, drawing on HSE and industry guidance and the specifications of the Noblelift range we supply.

Types of forklift truck: what each one is for

The general guidance in HSE's L117, Rider-operated lift trucks: Operator training and safe use, covers many types of lift truck, from counterbalanced and reach trucks to pallet stackers and very narrow aisle trucks. Most sites choose from four:

  • Counterbalance forklift: forks at the front and a counterweight at the rear to balance the raised load. HSE notes that on electric trucks the battery is part of the counterweight. Depending on the model, they work in warehouses, factories and outdoor yards. Our 28 forklifts run from 0.8 t to 18 t; you can compare each counterbalance forklift for sale in the range.
  • Reach truck: a warehouse truck that is typically kept stable by support legs extending in front of it and a heavy battery at the rear. A retractable mast keeps it compact in racked aisles. Ours are electric, rated at 1.5 t to 2.5 t, in sit-on, stand-on, scissor-reach and cold store versions.
  • Electric stacker: usually pedestrian-operated, for lighter stacking work in compact storage areas. Our electric pallet stackers take 600 kg to 2 t, in straddle-leg, counterbalanced, pedestrian and ride-on designs.
  • Pallet truck: moves pallets just clear of the floor. Our hand pallet trucks have a maximum fork height of 190 to 200 mm and have no drive battery to charge; electric versions come as pedestrian, platform and ride-on models. Each Noblelift pallet truck in our range is rated between 1.5 t and 3.6 t.

Aisle width: reach truck vs counterbalance forklift

Aisle width is the minimum space a truck needs to turn into the racking to place or retrieve a load. Manufacturers' data sheets usually work it out from the turning radius, the load's dimensions and the load distance, plus a safety clearance, commonly 200 mm. Measure between your racking and compare it with the figure on the data sheet.

Counterbalance trucks have a wider turning circle and suit more open spaces. A reach truck's retracting mast and compact chassis let it work in narrower racked aisles. Our spec tables show, where a figure is given:

  • Reach trucks: 2,720 mm to 2,975 mm (1000 × 1200 mm pallets, crossways).
  • Stackers: mostly 2,167 mm to 2,586 mm on the same basis; the PS12/16/18CB counterweight stackers need 3,110 mm to 3,360 mm.
  • VNA trucks: 1,600 mm to 1,700 mm (1200 × 800 mm pallets).

Lift height and load weight: what size forklift do I need?

Start with your highest racking beam and allow extra clearance above it, typically 150 to 200 mm, so the operator has room to place the load. Then check the truck can carry your heaviest load at that height.

HSE L117 defines actual capacity as the maximum load that can be carried at a set distance from the heels of the forks to a specified height, as shown on the capacity plate or chart. Capacity falls as lift height and load centre increase, so a deep pallet at the top beam may exceed it. HSE says fitting an attachment, such as a clamp or fork extensions, requires the truck to be derated and a new capacity plate fitted before use. Weigh and measure your heaviest loads; don't estimate.

Our reach trucks list lift heights from 5.5 m (RT15Q) to 13.8 m (RT15DP-H scissor reach), and our stackers lift up to 5,430 mm. Compare lift heights across our reach trucks for sale.

Floors, outdoor work and loading bays

HSE says lift truck surfaces should be as level and firm as possible, and that potholes and loose material are particularly hazardous to small-wheeled trucks. It also notes that solid tyres are generally fitted to warehouse trucks on smooth surfaces, and pneumatic tyres to rough-terrain and larger trucks. Reach trucks are generally used indoors, while counterbalance trucks, depending on the model, also work outside. Our rough terrain forklifts, two- and four-wheel drive from 1.8 t to 3.5 t, are built for yards, construction sites and uneven ground.

Loading and unloading lorries is a common counterbalance job, and HSE asks for extra care with curtain-siders, which have no edge protection. At a dock, electric pallet trucks are often used to move inbound and outbound goods, and some stackers can load lorries via a loading bay or tailgate. If a truck drives onto a trailer, HSE says the trailer should be braked, its deck strong enough to support the truck and load, bridge plates securely fixed, and the landing legs able to take the extra weight.

HSE also says trucks should never be driven up or down gradients above the manufacturer's maximum, and dock levellers should not be extended to a steep slope. In our range, where the spec gives a figure, electric stackers are rated for 4% to 8% laden, electric pallet trucks for 6% to 10% laden, and counterbalance forklifts for 15% to 35%.

Shift length and travel distance

Working hours and travel distance decide manual or powered, stacker or reach truck:

  • Hand pallet trucks: usually enough for short distances, typically under about 30 metres, depending on the load.
  • Electric pallet trucks: pedestrian models generally suit short distances and rider platform models longer ones. Ours are designed for longer runs, heavier loads and full-shift use.
  • Stackers: light-duty stackers are generally intended for occasional use, a few lifts and movements a day, with heavier-duty machines for frequent work.
  • Reach trucks: ours are designed for operators working at height across a full shift.
  • Battery type matters for long shifts; see our guide to lithium vs lead-acid vs diesel forklifts, which also covers HSE's advice on diesel exhaust indoors.

When a very narrow aisle truck makes sense

VNA trucks work in racking where the truck doesn't turn to face the rack. Our very narrow aisle trucks need 1,600 mm (VDE-160) or 1,700 mm (OPX15 and OPK-160) for 1200 × 800 mm pallets, and the OPX15 is listed with lift heights up to 13 m. That puts more pallets on each square metre of floor when you can't extend the building. VNA also needs:

  • A very flat floor: VNA trucks typically have no suspension, so floor imperfections are amplified at height. The Concrete Society's TR34 sets 'defined movement' flatness limits for VNA floors, and says the VNA truck maker's recommendations should also be sought.
  • Guidance: rails along the racking or a wire buried in the floor.
  • Other trucks for horizontal transport, with pick-and-drop stations to transfer pallets between the VNA area and the rest of the warehouse.
  • Early planning: TR34 notes defined-movement limits can't be set unless the exact VNA layout is known before construction.

Getting help choosing

If you would rather talk it through, Pristine Material Handling is an authorised Noblelift dealer with UK-wide delivery. You enquire; we work through the specification and survey your site, remotely or with a visit; you receive a written quotation with the full specification; and we deliver and hand over the truck with operator familiarisation.

Handover familiarisation is not a substitute for operator training. Under regulation 9 of PUWER, employers must make sure operators are adequately trained, and HSE's L117 sets out the basic, specific job and familiarisation training expected for rider-operated lift trucks.

Have your aisle widths, top beam height, heaviest load and pallet sizes to hand. You can request a quote or contact us on 0131 605 0238, Monday to Friday, 8am to 4pm.

Sources

FAQs

Common questions

What is a counterbalance forklift?

A forklift with the forks at the front and a counterweight at the rear to balance the raised load, so it needs no support legs. Depending on the model, it can work indoors and outdoors and load lorries. The forklifts in our range run from 0.8 t to 18 t.

Reach truck vs counterbalance forklift: which suits a warehouse?

For indoor racking with narrow aisles and high beams, usually a reach truck; where the spec gives a figure, ours need aisles of 2,720 mm to 2,975 mm for 1000 × 1200 mm pallets crossways. For yards, lorries, heavy loads or mixed indoor and outdoor work, usually a counterbalance forklift.

Pallet stacker vs forklift: when is a stacker enough?

When loads are light, lifts moderate, floors smooth and indoors, and use light to moderate. Our stackers take 600 kg to 2 t and lift up to 5,430 mm, but they are rated for only 4% to 8% gradients laden, so they don't suit steep ramps.

Reach truck vs pallet stacker: what's the difference?

A stacker is usually pedestrian-operated, lifts lower and suits lighter use. A reach truck carries the operator, lifts higher (up to 13.8 m in our range) and suits full shifts at height. In our range it needs a wider aisle than most of our stackers, though our counterweight stackers need more room than either.

What size forklift do I need?

Size it by your heaviest load at your highest lift. Capacity is rated at a set load centre and height and falls as either increases; attachments reduce it further and need a new capacity plate. Allow about 150 to 200 mm above your top beam and check the capacity chart.

Do I need a manual or an electric pallet truck?

Manual trucks suit short runs, typically under about 30 metres depending on the load, and have no drive battery to charge. For longer distances, heavier loads or full shifts, choose electric; rider platform models are designed for longer runs.

Ready to talk about your site?

Tell us what you move, how high it goes and what the floor is like — we'll come back with the right specification and a written quotation.

Request a quote Call 0131 605 0238