What Type of Material Handling Equipment Do I Need? Complete UK Buying Guide

Choosing the right material handling equipment can make a major difference to productivity, safety and day-to-day efficiency.

The best product depends on what you need to move, how heavy the loads are, how far they need to travel, whether lifting is required and how frequently the equipment will be used.

From simple manual pallet trucks through to powered stackers and lifting equipment, there are different solutions for different working environments.

In this guide, we look at the main types of material handling equipment available from Material Handling UK and explain where each one may be most suitable.

Hand Pallet Trucks

Hand pallet trucks are one of the most widely used forms of warehouse equipment.

They are designed to lift pallets slightly off the floor so they can be moved manually from one location to another.

Typical applications include:

• Warehouses
• Stockrooms
• Workshops
• Retail environments
• Loading areas
• Distribution centres
• Manufacturing facilities

A hand pallet truck can be a particularly good choice where loads only need to travel short distances and powered assistance is not necessary.

They are generally simple to operate, easy to maintain and can be an economical choice for everyday pallet movement.

When Is a Hand Pallet Truck the Right Choice?

A manual pallet truck may be suitable if:

• pallets are moved relatively short distances
• loads are within the truck's rated capacity
• floors are smooth and level
• pallet movement is occasional or moderate
• operators do not need powered travel
• lifting height beyond normal pallet clearance is not required

For many businesses, a reliable hand pallet truck is an essential piece of equipment.

Browse our range of hand pallet trucks.

Electric Pallet Trucks

Where pallets need to be moved more frequently or over longer distances, an electric pallet truck can reduce the physical effort required from the operator.

Electric pallet trucks use powered travel to move loads rather than relying entirely on manual force.

They can be particularly useful in:

• larger warehouses
• distribution centres
• busy loading areas
• production facilities
• environments with frequent pallet movement

Powered travel can help improve productivity when operators are moving heavy pallets throughout the working day.

Hand Pallet Truck vs Electric Pallet Truck

One of the most common choices is between manual and electric pallet trucks.

A hand pallet truck is often attractive because it is simple, economical and requires very little setup.

An electric pallet truck may be more suitable where:

• pallets are particularly heavy
• travel distances are longer
• pallets are moved very frequently
• reducing manual effort is important
• productivity is a priority

The correct choice depends on how the equipment will actually be used.

If a pallet is only moved a few metres occasionally, a manual truck may be perfectly adequate.

If operators are moving pallets repeatedly across a large warehouse, an electric model may offer significant benefits.

Browse our electric pallet trucks.

Weighing Pallet Trucks

A weighing pallet truck combines pallet movement with built-in weighing capability.

This can allow loads to be weighed without first moving the pallet onto a separate floor scale.

They can be especially useful in businesses where knowing the weight of goods is part of the normal handling process.

Typical applications may include:

• goods-in areas
• dispatch departments
• manufacturing
• logistics
• stock control
• freight preparation

By combining two processes into one piece of equipment, weighing pallet trucks can help save time.

Why Use a Weighing Pallet Truck?

A weighing pallet truck can be useful where businesses regularly need to know pallet weights before goods are moved or dispatched.

Potential benefits include:

• reducing unnecessary pallet handling
• quicker weight checks
• easier dispatch preparation
• improved workflow
• fewer separate weighing stages

The level of accuracy required should always be considered when choosing a weighing truck.

Browse our range of weighing pallet trucks.

Pallet Stackers

Pallet stackers are designed not only to move palletised goods but also to raise them to a greater height.

This makes them fundamentally different from standard pallet trucks.

A pallet stacker can be used for tasks such as:

• stacking pallets
• placing goods onto racking
• loading raised platforms
• positioning pallets at working height
• lifting goods within storage areas

Stackers are available in different designs, lift heights and capacities.

Pallet Truck vs Pallet Stacker

A pallet truck is primarily used to move pallets horizontally.

A pallet stacker adds the ability to lift pallets vertically.

If your requirement is simply to move pallets around the warehouse, a pallet truck may be enough.

If you need to raise pallets onto racking or position them at different heights, a pallet stacker is usually the more appropriate type of equipment.

Browse our pallet stackers.

What Should I Consider When Choosing a Pallet Stacker?

Important considerations include:

• maximum load capacity
• required lift height
• fork dimensions
• pallet type
• aisle width
• overall machine dimensions
• manual or powered movement
• battery and charging requirements
• floor conditions

The maximum rated capacity of the stacker should never be exceeded.

It is also important to remember that capacity can vary depending on lift height and load centre, so always check the manufacturer's specification for the exact machine.

Scissor Lifts

Scissor lifts are used where a load, platform or working surface needs to be raised vertically.

They work using a crossed scissor mechanism that expands as the platform rises.

Depending on the model, scissor lifts can be useful for:

• raising goods to working height
• loading and unloading
• assembly work
• maintenance
• production environments
• reducing unnecessary bending or lifting

They can provide a practical solution where items regularly need to be raised and lowered during a working process.

When Is a Scissor Lift Useful?

A scissor lift may be appropriate where goods need to be positioned at a more comfortable working height.

For example, repeatedly lifting products from floor level can place unnecessary strain on employees.

A scissor lift can allow a load to be raised closer to waist height, potentially improving the working position for repetitive tasks.

The correct model will depend on factors including load capacity, platform size and required lift height.

Browse our range of scissor lifts.

How Much Weight Do You Need to Move?

Load capacity should be one of the first things considered when buying material handling equipment.

Always determine the maximum realistic load rather than only considering an average pallet weight.

Equipment should never be used beyond its rated capacity.

For example, if your heaviest pallets regularly weigh 1,500kg, choosing equipment rated at exactly 1,500kg may provide very little margin.

It can be sensible to choose equipment with appropriate capacity above your normal working load, while following the manufacturer's guidance.

Check Your Pallet Dimensions

Not all pallets are identical.

Before ordering a pallet truck or stacker, check:

• pallet length
• pallet width
• fork entry direction
• fork spacing
• required fork length
• underside clearance

Standard equipment may suit common UK and European pallets, but unusual or specialist pallets can require different fork dimensions.

Consider the Distance the Load Will Travel

Travel distance is another important factor.

For short, occasional pallet movements, a hand pallet truck may be the simplest solution.

For repeated movement over longer warehouse distances, an electric pallet truck may reduce operator fatigue and improve productivity.

Think about the actual route rather than simply the size of the building.

Consider Floor Conditions

Material handling equipment performs best on suitable floors.

Check for:

• slopes
• damaged concrete
• thresholds
• ramps
• uneven surfaces
• debris
• tight turning areas

Wheel and roller choice can also affect how easily equipment moves across different floor surfaces.

Do You Need to Lift or Just Move?

This is one of the simplest ways to narrow down the right type of equipment.

If you only need to move pallets from one place to another:

Choose a hand pallet truck or electric pallet truck.

If you need to weigh pallets while moving them:

Consider a weighing pallet truck.

If you need to lift pallets onto racking:

Look at pallet stackers.

If you need to raise goods or a work platform vertically:

Consider a scissor lift.

Manual or Powered Equipment?

Manual equipment is often attractive where simplicity, lower purchase cost and occasional use are the main priorities.

Powered equipment can become more valuable as workload increases.

Consider powered equipment if:

• loads are moved frequently
• pallets are particularly heavy
• travel distances are substantial
• productivity needs to increase
• operator fatigue is a concern

The cheapest purchase price does not always mean the lowest overall operating cost if the equipment is used heavily every day.

Think About Frequency of Use

A pallet truck used a few times per week has very different requirements from one operating continuously throughout a warehouse shift.

For heavy daily use, consider:

• build quality
• serviceability
• replacement parts
• wheel durability
• battery runtime on electric equipment
• charging time
• warranty
• after-sales support

Matching the machine to the workload can help improve reliability and working life.

Safety and Training

Material handling equipment should always be used correctly and within its rated capacity.

Operators should understand:

• the controls
• safe load limits
• correct pallet positioning
• safe travel
• pedestrian awareness
• workplace hazards
• charging procedures where applicable

Workplaces should also have appropriate procedures in place for inspection, maintenance and safe operation.

Which Material Handling Equipment Is Best for a Small Warehouse?

For a smaller warehouse with relatively short travel distances, a quality hand pallet truck may cover most routine pallet movement.

If pallets are moved regularly throughout the day, an electric pallet truck may be worth considering.

Where stock is stored vertically, a pallet stacker may also be necessary.

The correct combination depends on the layout and type of goods being handled.

Which Equipment Is Best for Goods-In and Dispatch?

Goods-in and dispatch areas often involve several different handling tasks.

A combination of equipment may therefore be useful.

For example:

A standard pallet truck can move incoming pallets.

A weighing pallet truck can check shipment weights.

An electric pallet truck can move goods efficiently across larger loading areas.

A pallet stacker can position stock onto storage levels where appropriate.

Choosing the Right Material Handling Equipment

Before purchasing, ask:

• What is the maximum load weight?
• What pallet sizes are used?
• How far will loads travel?
• How frequently will the equipment be used?
• Is vertical lifting required?
• Is built-in weighing required?
• How wide are the aisles?
• What are the floor conditions?
• Is powered travel beneficial?
• What lift height is required?
• Will the equipment be used indoors or outdoors?

Answering these questions will help narrow the choice considerably.

Explore the Material Handling UK Range

Material Handling UK supplies equipment for warehouses, workshops, logistics operations, manufacturing and general commercial applications.

Browse our ranges of:

Hand Pallet Trucks

Electric Pallet Trucks

Weighing Pallet Trucks

Pallet Stackers

Scissor Lifts

Need Help Choosing the Right Equipment?

If you're unsure which material handling product is best for your application, contact the Material Handling UK team.

Tell us the weight of the loads you need to move, the pallet dimensions, travel distance and whether you need lifting or weighing capability.

We can help you identify the most appropriate type of equipment for your workplace.

Browse the complete range at material-handling.uk.