PalletTrucks And Stackers

A manual pallet truck relies on hand-pumping the hydraulic jack and hand-pulling the load, making it ideal for light, occasional use over short distances. A powered stacker uses an electric motor to raise, lower and sometimes drive the unit, suiting higher-frequency lifting or stacking pallets at height. If you're moving loads regularly or need to lift beyond waist height, a stacker will save time and reduce operator strain.

Standard pallet trucks typically handle 2000kg-2500kg, which covers most UK standard pallets loaded with goods, though heavy-duty models go higher for dense or industrial loads. Always check the actual laden weight of your heaviest pallet, not just the average, and build in a safety margin. Undersizing a truck causes premature wear on the hydraulics and increases the risk of failure under load.

Standard polyurethane wheels are designed for smooth, level indoor floors such as concrete or resin — they roll easily and don't mark the surface. For rough or uneven ground, gravel, or worksite conditions, look for models with pneumatic or nylon wheels built for durability outdoors. Using the wrong wheel type on the wrong surface leads to harder pushing, faster wear and potential tipping on debris.

Manual pallet trucks generally don't require formal certification, though basic operator familiarisation is sensible under general health and safety duties. Powered stackers, particularly ride-on or higher-lift models, should only be used by staff who've had proper instruction, as they fall under PUWER (Provision and Use of Work Equipment Regulations). Your employer is responsible for ensuring operators are competent and that equipment is regularly inspected.

Most pallet trucks and stackers come with forks sized around 1150mm long by 540mm-685mm wide, which fits standard UK and Euro pallets comfortably. If you're regularly handling non-standard or oversized pallets, check the fork spread and length before ordering, as a mismatch can make loading unstable or impossible. Some models offer adjustable fork widths for handling mixed pallet sizes.

Check the hydraulic fluid level periodically and keep the pump mechanism free of dust and debris, as grit is the most common cause of a truck failing to lift. Wheels and bearings should be inspected regularly for wear, especially if used on rough or outdoor surfaces, and any chassis damage should be addressed before it affects the lifting mechanism. A quick daily visual check before use, alongside routine servicing, will significantly extend the working life of the unit.