You may have unwittingly seen them in garden centres, DIY stores, on building sites or even in your own place of work, perhaps tucked into a stockroom. But what is a pallet truck?
These nifty pieces of manual handling equipment are essential devices for moving palletised goods across all sorts of working environments, and in this introductory guide, we’ll be interrogating how they work in practice and lifting the lid on their surprisingly long history.
There’s no time for dawdling – let’s get stuck right in.
Skip to:
- What are Pallet Trucks?
- Key Functions & Benefits
- The Core Types of Pallet Trucks
- How They Work
- Buying Considerations
- Top Picks
- Safety Essentials
- Conclusion
So, What is a Pallet Truck (Pallet Jack) According to the Specialists?
Pallet trucks have many aliases: pallet jacks, pump trucks or stacking trucks are each common. Similarly, depending on who you ask, the answer to our question will look quite different.
For instance, according to Merriam-Webster, pallet jacks are: “a lift truck for handling pallets”. But if you look up the definition with Collins, you’ll glean much more information; pallet trucks are “a powered truck with a mast, sometimes telescopic, on which slides a carriage which can be raised and lowered”. While this is a good start, let’s expand a little.
Pallet trucks feature a wheeled frame with forks designed to slide under pallets. An electric or hydraulic mechanism, operated by the handle, allows you to raise or lower those forks, thereby lifting the pallet off the ground. Here, 3 to 8 inches is standard for hand-operated models.
A Brief History
Now, you understand what a pallet truck is, let’s probe into the backstory. As you might expect, the history of manual handling equipment is deeply interwoven with the advent of the Industrial Revolution, but what you might not know is that these tools played an intriguing role in the women’s labour movement over the centuries. In fact, one could argue that pallet trucks helped equalise the playing field and reduce barriers to entry for women working in more blue-collar industries.
Take a look at the image above: it demonstrates one of the earliest iterations of the pallet truck, which started cropping up around 1918 as engineers made strides in automation. Although the device wasn’t patented, in the form we’re familiar with today, until 1939 by George Raymond, Sr., prototype versions were instrumental to women who were conscripted into the industrial workforce during the First World War.
Pallet Trucks vs Pallet Jacks vs Forklifts
In our experience as manual handling specialists, one of the most common misconceptions relates to the difference between pallet trucks, pallet jacks and forklifts; after all, they’re each similar examples of lifting equipment whose names get thrown about a lot. Let’s set things straight.
As we established earlier, pallet trucks and pallet jacks are interchangeable terms for the same piece of equipment – the hand-operated lifting device with forks that are typically used for the quick, low-lift movement of pallets in tight spaces.
Forklift trucks, however, refer to the larger vehicles with higher lifting capacity and vertical movement. There are many types, and where pallet trucks rely on lithium batteries, the latter are engine-powered.
Key Functions and Benefits
Pallet jacks serve a multitude of purposes across countless industries and settings, such as warehouses, building yards, distribution hubs and docks. This said, their generalised functions can be summarised as follows:
- Loading and Unloading: Moving goods on and off vehicles or storage areas.
- Transportation: Moving pallets within a warehouse, loading dock, garden centre and so on.
- Stock Management: Helping to organise, store, stack and move palletised stock.
The top line is that pallet trucks are built to support workers moving heavy items across shorter distances, thereby limiting the manual handling required and mitigating the associated hazards. Thanks to their powerful load capacity and slick hydraulic system, it’s the frame and forks that bear the majority of the weight, allowing staff respite during pressured working days. Here is a handful of other benefits worth pondering over:
- Baked-In Safety Features: The brake on the handle means that with a push of a button, workers can lock on the brakes and immobilise the device, preventing rolling – even on uneven surfaces.
- Compliant: As explored in our manual handling risk assessment guide, the right equipment ensures that your business remains compliant with Health and Safety legislation.
- Lift Heavier Loads: Standard pallet jacks can carry loads up to 40 times heavier than those of their human counterparts, and the best electric models up to 150 times more.
- A Budget-Friendly Way to Enhance Operational Efficiency: A convenient solution to tight budgets, pallet trucks streamline systems and reduce physical strain on workers, which improves overall productivity.
- Complements Automated Systems: As our Director, Phil Chesworth, explained in a recent article, “Automation and AI are fantastic tools when deployed in the right context, but they’re not a silver bullet”. The versatility of pallet trucks allows businesses to insulate themselves against financial uncertainty and prevents them from putting ‘all their eggs in one basket’, so to speak.
The Core Types of Pallet Trucks
There are many types of pallet trucks on the market, each with a particular specialism and related features. In the interest of time, allow us to blitz through the core examples.
- Manual Pallet Trucks: The most well-known variant, operated by a hand-pump hydraulic system and featuring a brake on the handle.
- Electric Pallet Trucks: A more automated version of the manual hand model, providing extra machine assistance, with variable drive speed control and intuitive LCD displays.
- Sem-Electric Pallet Trucks: A hybrid of the two previous types, combining some manual lifting with electric-assisted lifting, and a great compromise on functionality and budget.
- Ride-On Pallet Trucks: What is a ride-on pallet truck, you ask? Exactly what it sounds like: a pallet jack with an integrated driver’s stand or seat designed for on-board operation. This is ideal in logistics environments where fatigue and strain ought to be minimised.
- Rough Terrain Pallet Trucks: Designed for external use or on uneven problem-surfaces, these pallet trucks combat the terrain with wider, more robust tyres.
- Low-Profile Pallet Trucks: Pallet trucks with a lower frame that can traverse environments wherein pallets or skids need to pass by with low clearance.
- Heavy Duty Pallet Trucks: It’s in the name – pallet trucks built to withstand much more demanding loads, sometimes up to 5000kg.
- Mini Pallet Trucks: Often used in the context of retail, these pint-sized pallet trucks offer the benefits of the standard models in miniature, helping move smaller loads in limited space, where high load-bearing capacity isn’t a priority.
How Does a Pallet Truck Work?
We’ve explained what pallet jacks are, but how does a pallet truck work in practice? Allow us to explain in more detail…
As we mentioned, pallet trucks operate with a combination of hydraulics and electrics, depending on the model. What they all have in common, though, is an underlying mechanism. Here’s that process step-by-step:
- Insert the Forks: The tapered forks are inserted into the openings of a pallet and secured in place, ensuring the control lever is neutral and thereby locks the load in place.
- Let the Hydraulic/Electric Mechanism Do Its Work: A pump handle (manual version) or a motor (electric version) is used to force hydraulic oil into a cylinder, which lifts the forks and the pallet off the ground.
- Manoeuvring the Pallet Truck: The operator steers the truck by pushing or pulling it with the handle, making sure to follow safety protocol for moving the device.
- Lowering the Loads: A lever on the handle is pulled, which forces open a valve and releases the hydraulic oil back into the tank, and this slowly lowers the forks towards the ground.
Key Buying Considerations
Selecting the right pallet truck for your workplace extends far beyond price tags. The best choice depends on your specific environment, the loads you regularly handle, and how often the equipment is going to be used. To provide an example, a distribution centre with frequent, heavy pallet movement may require a heavy-duty or electric model, while a small retail outlet might be better served with a compact and more lightweight manual option.
When assessing your options, think about:
- Load Capacity: Always check the maximum weight rating and compare it to the loads you expect to move.
- Environment: Rough terrain models are suited for construction sites or outdoor spaces, while low-profile trucks are designed for areas with reduced clearance.
- Frequency of Use: If your staff are using pallet trucks continuously throughout the day, electric or semi-electric models can help reduce fatigue and speed up processes.
- Budget: A cost-effective manual pallet truck may be enough for smaller operations, but larger sites may benefit from investing in electric models that improve long-term efficiency.
- Compliance and Safety: Make sure your chosen model complies with health and safety standards to protect both workers, goods, business operations and by extension brand reputation.
Pallet Truck Shop’s Top Picks
With so many options available, choosing the right pallet truck can be overwhelming. That’s why we’ve put together a detailed guide to some of the best models on the market, covering everything from reliable manual designs to high-capacity electric trucks.
Take a look at our official top picks list for in-depth recommendations, comparisons, and expert advice on which trucks perform best in different settings.
Safety Essentials
Maintaining adequate health and safety in busy environments like warehouses, garden centres, and construction sites requires an in-depth understanding of the regulations in play and a recognition that high standards should be your aim wherever pallet trucks are in use.
Training & Operational Procedures
First and foremost, staff should always follow standard operating procedures when stacking, loading, unloading, and manoeuvring pallets. Training in correct lifting methods and regular refresher sessions helps reinforce good habits and reduces the chance of injuries.
Equipment Checks
Routine equipment checks are equally important. Hydraulic systems, wheels, and brakes should be inspected before use, and spare batteries should be available for electric trucks to avoid downtime. Keeping equipment in good condition ensures it remains reliable during demanding shifts and helps extend its lifespan.
Picking the Right Pallet Truck from the Get-Go
Choosing the right truck from the start also plays a big part in workplace safety. The right procedures and equipment not only keep workers safe but also improve efficiency and reduce the risk of costly accidents. In busy warehouses, for example, accidents often spike among temporary staff who may not receive adequate training or be provided with the right tools for the job. Ensuring that every worker understands standard operating procedures and has access to suitable pallet trucks can significantly reduce such risks
Recapping on What a Pallet Truck Is
So, what is a pallet truck? At the very simplest, a manual handling device that operates with a hydraulic system and weight-bearing forks to make the manoeuvring of pallets straightforward, safe, and stress-free. With these insights, you can now consider yourself halfway there to becoming a veritable pallet truck pro – but, of course, the learning journey doesn’t stop there. For more information and insider knowledge, you can check out the rest of our industry blog.
Looking to improve your operational efficiency at work? Contact Pallet Truck Shop today for expert advice and product recommendations tailored to your needs.