Buying a reach truck or stacker: assess rack heights and pallet throughput

Start with the pallet and access at the rack feet

Whether a pallet is single-faced or double-faced, its fork openings and the clearance below the rack feet directly affect access. For a stacker with load legs, check whether the legs can enter the area where the load must be collected. A pallet that can be lifted in an open space may still be inaccessible when positioned close to a rack foot.

The brief should include front, side and underside photographs of the pallet and its position on the rack. Record any load projecting beyond the pallet because the actual working dimensions may be greater than those of the empty pallet. If the warehouse uses several pallet types, check every important group; do not accept the equipment with one convenient pallet and treat it as representative of the whole warehouse.

Lift height must be considered with residual capacity

When loads are stored at height, the buyer needs the load chart for the exact configuration rather than only the maximum lift-height figure. Identify the highest rack level carrying a heavy load and request confirmation of capacity under that condition. The mast, load centre, forks and options must be recorded with the proposal so that data from another configuration is not applied.

A reach truck does not automatically replace every stacker, and a stacker is not restricted only to low warehouses. A meaningful difference must be demonstrated through the actual work. For loads whose centre of gravity is difficult to determine or pallets that vary, request an additional assessment instead of choosing an intuitive safety margin. Clear capacity limits help shift managers organise work after handover.

Comparison checklist for the purchasing team

Compare aisle requirements using the actual working pallet

Ast is usually stated for a particular pallet and operating method. When comparing two trucks, therefore, use the same pallet dimensions, direction of approach and load-handling requirement. Include end-of-aisle clearance, column guards and waiting loads on the layout; measuring only the distance between two rack rows may miss the most difficult turning point.

A technical proposal should show the entry route, the point where turning begins and the fork-entry position. During a trial, observe repeated operations rather than only one movement prepared in advance by the driver. If the trial takes place somewhere other than the actual warehouse, record which aspects have been demonstrated and which still require an on-site check. Do not extend the trial result beyond its scope.

Throughput determines how the fleet should be organised

A warehouse handling a few batches each day has different requirements from one with continuous movements to and from high rack levels. Make a table of pallet numbers by time period, average travel distance and waiting at aisle entrances. The proposal should calculate productivity for the whole route because increasing truck speed offers little benefit if the bottleneck is in receiving or pallet supply.

Operating posture, visibility and travel distance should also be considered across a full shift. These factors are difficult to show in one price line, but they affect equipment suitability. Do not reduce the entire decision to which truck is cheaper; compare the cost of achieving the same service level, including truck quantity, energy-replenishment schedule and coordination between areas.

Check the floor and transition areas before ordering

Equipment used in racking warehouses must be compared with the actual floor flatness and condition under the configuration's instructions. Door thresholds, floor joints and transition areas can affect the working route. Do not assume that a machine described as a warehouse truck can travel over a dock leveller, rough yard or into a container.

If pallets must be collected from a lorry and then placed in racking, describe the complete sequence. One truck may suit the whole route, or two equipment groups may need separate duties. A split-route proposal must include pallet handover time and the intermediate space. Buying for only one leg and adding another truck later often leaves necessary items out of the initial cost plan.

Put both options into one decision table

The comparison should cover pallet compatibility, capacity at the highest level, aisle requirement with the actual pallet, floor, peak pallet volume, energy and support scope. Mark each row as meets, does not meet or insufficient data. Compare price only between options that satisfy mandatory requirements; an unresolved point must not be treated as compliant.

The ACE C&T catalogue includes sit-down and stand-on reach trucks and stackers as references for Hangcha configurations. This does not confirm stock availability or suitability for every project. The selling price, exact configuration, supply schedule and handover conditions are confirmed after the requirement is discussed. Providing the rack plan and pallet photographs at the start helps the consultation focus on the warehouse's real differences.

Frequently asked questions

Is knowing the rack height enough to select a reach truck?

No. Capacity at the working height, pallet type, aisle, floor and throughput are also needed before selecting a configuration.

Can a stacker handle every pallet type?

This should not be assumed. Check the pallet underside, load legs, rack feet and the exact equipment configuration.