The Complete Guide to Choosing the Right Pallet Truck for Your Business

Efficiency is everything in the growing industry of warehousing, logistics, loading, and unloading. The pallet truck is essential for numerous material handling processes. Irrespective of whether your company runs a dairy store, a distribution center, or a factory, using the right pallet truck will positively affect your operating efficiency, employee safety, and ultimately your bottom line. 

What is a pallet truck? 

 Pallet trucks (or pallet jacks or pump trucks) are material handling equipment that assist in moving, lifting and transporting palletized products, materials and goods over short distances. Pallet trucks are very diverse in their capabilities and are used by many industries including retail, manufacturing, warehousing and distribution. 

What types of pallet trucks exist in the marketplace? 

 There are many different types of pallet trucks available in the marketplace, having different functions and use: 

Manual pallet trucks or hand pallet trucks  

Manual pallet trucks or hand pallet trucks are widely available (the cheapest) and likely the most common type of pallet truck you will find on the market today. Manual pallet trucks work similar to a hydraulic pump mechanism, where the operator can pull down on each of the handles to raise and move the pallet using a tiny amount of force. Hand pallet trucks are made up of two forks that slide underneath the pallet, have a hydraulic jack that will raise the load, and have wheels that rotate to turn the truck.  

Benefits:  

• They are an inexpensive solution compared to other types of material handling equipment.   
• No power requirements or battery replacement   
• Low upkeep and maintenance expenses   
• Compact to fit into tight spaces   
• It can be used in light- to medium-use applications.    

Considerations:   

• Effort required of the operator   
• Lifting height is limited to about 7-8 inches (maximum).   
• It works best on flat, smooth surfaces.   
• Weight limitations vary but typically range from 2,000 to 5,500 pounds.   
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Hydraulic Hand Pallet Trucks  

This is where hydraulic hand pallet trucks belong in the pallet truck family. The operator controls the hydraulic pressure to lift, resulting in smooth lifting operations that require minimal effort from the operator. For lifting heavy loads, the hydraulic system adds to the amount of force applied by the operator to lift that load with all but reasonable physical effort.    

Benefits:  

• Simple mechanics and reliable operation   
• Variety of configurations and weight capacities   
• No charging or fuel requirements   
• Less upfront cost than powered options    

Considerations:  

• A proper hydraulic system is maintained.   
• Operator training is necessary to avoid strain injuries.   
• Performance is based on the quality of floor surfaces.   

High-Lift Pallet Trucks  

High-lift pallet trucks expand material handling capabilities even further by providing an extended vertical lift.  Standard pallet trucks raise loads only a few inches off the ground (typically 3-4 inches), while high-lift pallet trucks can elevate pallets to working heights of several feet.  

Benefits:  

• Dual functionality, as both transport and work positioning equipment 
• Eliminates the need for separate lifting equipment in some applications. 
• This equipment reduces employee strain caused by bending or reaching. 
• Enhances productivity for picking, stacking, and loading operations.  

Considerations:  

• The purchase price is higher than that of standard pallet trucks. 
• May require more operator training 
• Additional maintenance requirements 
• Heavier and potentially less maneuverable when fully loaded 

Electric Pallet Trucks  

Electric pallet trucks introduce powered operation to material handling applications, dramatically cutting down on operator effort. These battery-powered vehicles incorporate electric motors that take care of both lifting and travel functions. 

Benefits: 

• Significantly reduced physical demands on operators 
• Higher productivity and efficiency 
• Better for repetitive or continuous operations 
• Available with various control options (walk-behind, stand-on, etc.) 
• Some models have advanced capabilities, such as scales or positioning systems. 

Considerations:  

• Higher initial investment   
• Requires charging infrastructure for the batteries   
• It's much more complex to maintain.   
• It requires training to operate safely.   
• Heavier than a manual option 
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Key Considerations When Choosing a Pallet Truck  

Once you've identified the right pallet truck, the next step is to analyze the key considerations:    

1. Load Capacity Requirements   

Pallet trucks don't have the volumetric capacity that forklifts have. The weight of the materials you will likely be handling should determine your pallet truck's load capacity. Standard pallet trucks are typically in the 2200-5500 lb. (1,000 kg-2,500 kg) range; however, heavy-duty options exist that are capable of handling much higher weights.  

It's best to slightly oversize... generally you should select a pallet truck with a capacity rating that is at least 10-15% greater than your typical maximum load. 

2. Operating Environment   

The conditions created in your facility can affect the selection of a pallet truck:   

• Floor condition: All pallet trucks work best on smooth, even surfaces. Rough and uneven floors might necessitate pallet trucks with larger diameter wheels or with specialized ramps or other components built for the conditions. 
• Temperature: Standard pallet trucks will typically function properly in ambient temperatures. Cold storage or freezer environments would necessitate low-temperature hydraulic fluids and components.   
•  Cleanliness requirements: Selected pallet trucks for use in food, pharmaceutical, or cleanroom operations may need to specify stainless steel or corrosion-resistant models.   
• Indoor vs. outdoor: Pallet trucks used for outdoor applications will require some weather-resistant features and appropriate wheels for traveling on various outdoor surfaces.   

3. Fork Dimensions and Configurations  

 Pallet trucks have different forks, lengths, widths, and forks for different pallet styles: 

• Standard forks: typically 48" in length for normal 48 x 40" pallets.   
• Extended forks: to 96" for oversized loads.   
• Narrow forks: designed for specialized pallets or fit. 
• Wide forks: Intended for specific loads that require extra stability.   

Note that the width between the forks (fork span) should match your pallet construction so that you have the best support and stability. 

4. Wheel Options 

Wheels have a lot to do with performance: 

• Polyurethane wheels: Provide a good balance of durability and floor protection; good for almost every indoor use.   
• Nylon wheels: Great floor protection with a higher load capacity; good for smooth surfaces.   
• Rubber wheels: provide good shock absorption for uneven surfaces, but they have durability drawbacks.   
• Steel wheels: Excellent durability for rough environments, but could damage the floors.   

Be aware of the load wheels located under the forks and the steering wheels, as they depend on the conditions of your facility. 

5. Ergonomics and Operator Comfort  

For companies with heavy pallet truck usage, ergonomic design factors also become very important:  

• Handle design: you want grips that are comfortable and allow natural hand positioning.   
• Control accessibility: you want levers/controls that are easy to reach and operate.   
• Turning radius: better maneuverability when making tight turns is helpful in limited space. 
• Noise: If you work with clients or are often in such environments, consider the truck's noise level. 

6. Maintenance and total ownership cost  

Consider ongoing costs in addition to the initial purchase cost:  

• Serviceability: How serviceable is the unit?   
• Parts availability: How easy are replacement parts to source?   
• Service intervals: How frequently does the unit require servicing? 
• Expected service life: A more expensive truck with more quality components will usually give a better ROI over time. 
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Special Applications and Specialized Pallet Trucks 

Certain applications necessitate pallet trucks with specific requirements: 

Scale Pallet Trucks  

These integrated scales enable operators to weigh a load while moving it, which helps to make inventory tracking and shipping processes more efficient. 

Low-Profile Pallet Trucks  

These pallet trucks have a minimum fork height that is lower than that of a standard pallet truck, allowing them to handle special pallets or containers that standard pallet trucks cannot access.   

Corrosion-Resistant Pallet Trucks   

In these pallet trucks, stainless steel is used in their construction, or special coatings are used to enable these trucks to withstand either washdown procedures, wet environments, or corrosive materials.   

Explosion-Proof Pallet Trucks   

We specifically designed these trucks for hazardous environments where standard electrical components may create ignition hazards. 

Safety Considerations  

Ensure that any operators using safety techniques are involved in safe operation. 

• Inspection: Unless a schedule is in place, it is best to incorporate inspection into pre-use before every use. 
• Load location: Train operators on the basics of load placement and balancing when using the equipment. 
• Safety Gear: Make sure to wear the appropriate footwear on pallet truck thoroughfares. 
• Traffic: Introduce pallet truck traffic rules. 

Making Purchase Decisions  

When you decide to buy pallet trucks, here are other issues to consider: 

New Equipment vs. Used Equipment  

New equipment will typically have a full warranty and new features; however, for those businesses with small budgets, used pallet trucks can offer excellent value. If you are considering used equipment, pay attention to :

• General condition and any signs of regular maintenance 
• Age and hours used 
• Availability of service/replacement parts 
• Expected remaining useful life 

Renting vs. Buying  

If you have seasonal needs, a special project, or simply a functional need for a pallet truck, renting it might be a more efficient use of resources than buying one. Think about:

• How long do you need it for?   
• How often do you expect to use pallet trucks? 
• If you decide to buy pallet trucks, will you have a place to store them when they are not in use?   
• Any potential tax implications (e.g., tax deductibility for rental/purchase)  
  
  
   

Consider the cash flow implications of a one-time cash outlay compared to renting or making monthly payments. 

Finding a Trusted Supplier 

Make sure you partner with trusted suppliers that provide: 

• Quality products from well-known manufacturers. 
• Outstanding warranties 
• Good quality service and technical support, if requested 
• They offer fair prices and policies for the products they sell. 

Finding good quality pallet trucks in India 

If you are a business buying material handling equipment in India, then you will need to find suppliers that you can trust so that you can make a good purchase. Aajjo is a popular B2B marketplace in India that lists pallet truck suppliers from all over the country. 

Aajjo makes it numerically possible to compare a few different vendors with options, specifications, and prices, giving you an opportunity to make a meaningful purchasing decision without contacting each supplier to view their equipment. 

Aajjo is an easy way for you to find anything from the simplest manual pallet trucks to the professionally designed electric pallet trucks with components that fit your company's needs. Additionally, Aajjo's verification process provides reassurance that you are dealing with legitimate suppliers that are providing you with excellent equipment.   

Maximize Your Investment   

After you have found the right pallet truck for your business, there are some best practices to optimize your return on investment: 

Training  

Even the simplest manual pallet trucks require training in order to operate the equipment as efficiently and safely as can be and to ensure the equipment does not get damaged.  Develop a standardized training program covering:  

• Safe operating procedures. 
• Weight limitations 
• Proper lifting and lowering techniques 
• Maneuvering in tight spaces 
• Daily inspection requirements

Preventive Maintenance 

Regular maintenance significantly extends equipment life and prevents costly downtime.  

• Follow manufacturer-recommended maintenance schedules. 
• Check hydraulic fluid levels regularly. 
• Inspect wheels for damage or debris. 
• Keep moving parts properly lubricated. 
• Address minor issues before they become major problems. 

Operator Accountability  

Implement systems that encourage responsible equipment use: 

• Assign specific trucks to operators when possible. 
• Conduct regular performance reviews. 
• Recognize and reward proper equipment care. 
• Address misuse promptly. 

Conclusion 

Pallet truck selection will be based on the working conditions of your staff, the nature of your working environment, and the amount you have to spend. You will have a range from simple manual pallet trucks (seldom used) to advanced electric pallet trucks (high-use operation). Choosing correctly can result in increased productivity, fewer workplace injuries, and overall value through the life of the equipment.  

When you understand the distinctions between pallet trucks, from everyday hand pallet trucks to specialized high-lift pallet trucks, you will become a more informed, educated consumer, facilitating the attainment of your business objectives. And remember, the lowest total cost is not always the most cost-effective strategy.  

If you are a business in India, you can access a wide range of pallet trucks (of all types) from verified suppliers on Aajjo. Finding pallet trucks through this B2B marketplace meets sourcing requirements as well as provides real value for your money.    

A pallet truck should be more than simply a piece of equipment; it should be a productivity tool that you use to improve your operational efficiency, safety, and ultimately your profitability. Put in the time to correctly assess your needs, consult experienced suppliers, and have trust in a purchasing option that will improve your overall operational efficiency.