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Eight practical steps to choosing forklifts and other materials handling equipment. Whether you are equipping a new site, replacing ageing trucks, or improving an existing operation, working through them in order will help you avoid buying the wrong equipment.
Selecting the right materials handling equipment (MHE) is a strategic decision that directly impacts operational efficiency, workplace safety, and the bottom line. Materials handling equipment is a significant investment for many warehouse operations, so making well-informed choices is essential.
Each step builds on the last, from assessing your needs through equipment types, running costs and safety to choosing a supplier. The equipment and cost advice applies wherever you operate; where the rules differ, Step 6 covers the UK and the rest of Europe.
Before evaluating any equipment, conduct a comprehensive analysis of your current operations and anticipated future requirements. This assessment forms the foundation of every subsequent decision.
Work through each of the following areas systematically. Where possible, gather quantitative data rather than relying on estimates.
Material types: What are you handling? Pallets, cartons, rolls, drums, and specialty items each impose different requirements on equipment design and load handling.
Weight parameters: Establish average and maximum load weights, together with the frequency distribution. Over-specifying capacity wastes capital; under-specifying creates safety risks.
Actual lifting capacity: A truck sold as "2.5 tonnes" lifts that weight only at its rated load centre and up to a certain height. Its actual capacity (safe working load) falls when the load is longer or deeper than standard, when it is lifted higher, and when an attachment such as a clamp, rotator or fork extensions is fitted. Tell the supplier your heaviest load, its dimensions, the highest lift and any attachment, and check the truck's capacity plate or chart covers that combination. When an attachment is fitted, the supplier should work out the reduced capacity and fit a new capacity plate for the truck with that attachment before it is used.
Vertical requirements: How high do you need to lift? Consider stacking heights, racking configurations, and overhead clearance constraints.
Throughput volume: Quantify daily movement counts. Note peak periods and seasonal variations, as these often dictate the fleet size needed.
Environment: Indoor, outdoor, or mixed? Temperature extremes, hygiene standards, and hazardous area classifications (ATEX/DSEAR zones where applicable) all constrain the viable equipment pool. Cold store operation deserves particular attention: sub-zero environments affect battery performance, hydraulics, and condensation on electronics, and typically require cold-store-specification equipment and heated cabins for extended shifts.
Facility constraints: Aisle widths, floor condition, and clearances are covered in detail in Step 4 — but flag any known constraints now, as they shape which categories are worth evaluating at all.
Technology integration: Is compatibility with WMS, ERP, or automation systems required? Adding integration later can be more expensive.
PRO TIP: Spend the time to gather hard data at this stage. Buying the wrong equipment more often comes from an incomplete needs assessment than from poor equipment quality.
Materials handling equipment spans a broad spectrum, from simple manual tools to sophisticated automated systems. Understanding each category's strengths and ideal applications ensures you evaluate only what is relevant to your operation.
Pallet Trucks (Manual or Electric)
Pallet trucks are the workhorse of short-distance pallet movement, truck loading and unloading, and small warehouse operations. Manual versions are low-cost and maintenance-light; electric variants reduce operator fatigue during frequent use. Most manual and powered pallet trucks lift between about 1,300 and 2,500 kg; heavy-duty models are available for heavier loads. Best for: Ground-level transport over distances under 50 metres with minimal lifting requirements.
Stackers (Pedestrian or Rider)
Pedestrian stackers and their ride-on equivalents handle light to medium stacking in retail backrooms, workshops, small warehouses and order assembly areas. Capacities usually range from 1,000 to 2,000 kg, with lift heights to around 5 metres for pedestrian models and 6 metres for rider models. Best for: Compact, low-cost stacking of light loads in congested areas where a forklift cannot operate.
Counterbalance Forklifts (Electric, LPG, Diesel)
The general-purpose workhorse of medium to large warehouse operations, counterbalance forklifts handle capacities from 1,500 to over 8,000 kg with lift heights to 7 metres. They require aisle widths of 3.5 metres or more. Best for: Wide-aisle environments needing versatile equipment for varied load types and moderate lift heights.
Reach Trucks
Reach trucks are designed for high-density storage and narrow-aisle operations. Capacities range from 1,400 to 2,500 kg with heights reaching 12 metres or more, and they operate in aisles of 2.7 to 3.2 metres. Because the aisles are narrower, a reach truck layout can accommodate substantially more racking in the same floor area than a counterbalance layout. Best for: Maximising storage density while maintaining good throughput.
Very Narrow Aisle (VNA) Trucks
VNA trucks push storage density to its maximum. They handle 1,000 to 1,500 kg at heights up to 17 metres and operate in aisles as narrow as 1.6 metres using wire or rail guidance. However, they demand excellent floor flatness and significant infrastructure investment. Best for: Space-constrained, high-efficiency warehouses where the infrastructure investment is justified. Articulated forklifts reach similar aisle widths without guidance systems and are covered by our articulated narrow aisle specialists.
Order Pickers
Order pickers serve e-commerce fulfilment, parts distribution, and batch-picking operations. Available in low-level (to 2.5 m), medium-level (to 6 m), and high-level (to 12 m+) configurations, they are purpose-built for frequent individual item picks across high SKU counts.
Tow Tractors and Tugs
Tow tractors move multiple trailers in train formation, reducing trip frequency on assembly lines, in airports, and across large facilities with repetitive transport routes. They are the natural choice for moving many smaller loads over distances exceeding 100 metres.
Container Handlers
Reach stackers and empty container handlers are built for ports, intermodal yards, and distribution centres handling 20ft and 40ft shipping containers. Reach stackers lift laden containers at capacities of up to about 45 tonnes; empty container handlers stack empty boxes and typically lift 7 to 11 tonnes.
Cranes and Hoists
Jib cranes (fixed point), overhead cranes (bay coverage), and gantry cranes (portable) serve workshops, factories, and maintenance bays where loads exceed forklift capacity or dimensions.
Conveyor Systems
Available in roller (gravity or powered), belt, flexible, spiral, and sortation configurations, conveyor systems suit high-throughput distribution and production line integration with predictable, repetitive routing.
Docking Equipment
Dock levellers, yard ramps, vehicle restraints, and dock shelters improve speed and safety at the loading dock. Any operation loading or unloading multiple trucks daily should evaluate this equipment as a priority.
Pallet In-Feed Systems
Automated pallet supply systems serve manufacturing lines, bottling plants, and packaging operations, delivering consistent, high-volume pallet flow into production without manual intervention.
Automation in materials handling typically takes two forms, each suited to different operational profiles.
Automated Guided Vehicles (AGVs), including automated forklifts, travel set routes. Older systems follow wires, magnets or tape in the floor; modern ones navigate by laser using reflectors mounted around the building, or by recognising walls, racking and other fixed features, which makes routes easier to change. They suit stable, repetitive, high-volume movements.
Autonomous Mobile Robots (AMRs) plan their own paths and steer around people and obstacles, making them better suited to operations whose layout or workflow changes often. The line between the two is blurring, so judge each system by how it handles your routes rather than by its label.
PRO TIP: Automation is generally easiest to justify in multi-shift operations, where the investment is spread over more working hours. Evaluate AGVs where the environment is stable; choose AMRs where flexibility matters.
The following table compares the main equipment categories to help with initial shortlisting. The figures are typical ranges, not specifications: confirm the capacity, lift height and aisle width with the supplier for the specific truck and your load.
| Equipment Type | Capacity (kg) | Typical Lift Height (m) | Indicative Working Aisle (m) | Best For |
|---|---|---|---|---|
| Pallet Truck | 1,300–2,500 (more for heavy-duty) | — | N/A | Short-distance ground transport |
| Stacker | 1,000–2,000 | 5–6 | Varies | Light stacking, confined spaces |
| Counterbalance Forklift | 1,500–8,000+ | 7 | 3.5+ | General-purpose, wide aisles |
| Reach Truck | 1,400–2,500 | 12+ | 2.7–3.2 | High-density, narrow aisles |
| VNA Truck | 1,000–1,500 | 17 | 1.6 | Maximum density, guided aisles |
| Order Picker | Varies | 12+ | Varies | Piece picking, e-commerce |
| Tow Tractor | Varies | — | N/A | Long-distance, train formation |
The power source you choose significantly impacts operating costs, environmental suitability, and total cost of ownership. Each option has distinct advantages and limitations that must be weighed against your operational profile.
| Power Source | Best For | Advantages | Key Considerations | Typical Use Case |
|---|---|---|---|---|
| Electric (Lead-Acid) | Indoor, food/pharma | Zero emissions, quiet, lower energy costs | 8-hour charge cycle, battery maintenance, charging infrastructure | Clean, single-shift warehouses |
| Electric (Lithium-Ion) | Multi-shift operations | Fast/opportunity charging, maintenance-free, longer lifespan | Higher upfront cost (offset by operational savings) | 24/7 distribution centres |
| LPG | Mixed indoor/outdoor | Quick refuelling, good power output, versatile | Emissions require ventilation, fuel storage and handling per DSEAR/ATEX | Flexible operations, extended shifts |
| Diesel | Outdoor, heavy-duty | Maximum power, durability, all-weather | Generally for outdoor use: indoors only after careful assessment of exhaust emissions and ventilation; higher emissions, noise; new engines must meet Stage V emission limits, and check local low-emission zone rules | Construction, lumber yards |
| Hydrogen Fuel Cell | Large fleets, sustainability | 3-minute refuel, zero emissions, consistent power | Significant infrastructure investment, limited availability | Large-scale, sustainability-focused |
PRO TIP: Lithium-ion batteries are increasingly common in indoor electric equipment. For multi-shift operations in particular, opportunity charging and reduced maintenance often justify the higher initial investment — run the comparison over the full ownership period rather than on purchase price alone.
Your facility's physical characteristics determine which equipment will operate efficiently and safely. Document these parameters thoroughly before engaging with suppliers.
Aisle width: Measure your narrowest operational aisle. This single dimension often eliminates entire equipment categories from consideration.
Vertical clearance: Document ceiling heights, obstructions (sprinklers, lighting, HVAC), and maximum rack heights.
Floor condition: Assess levelness (critical for VNA and reach trucks), surface quality, and load-bearing capacity.
Access points: Note doorway dimensions, ramp gradients, and dock configurations.
Infrastructure: Verify electrical capacity for charging, ventilation requirements, and fuel storage options.
Typical working aisles for shortlisting only; the aisle a truck actually needs depends on the model, the pallet size and the load, so ask the supplier to confirm it.
| Aisle Width | Suitable Equipment | Storage Density |
|---|---|---|
| 3.5 m+ | Counterbalance forklifts | Standard (baseline) |
| 2.7–3.2 m | Reach trucks | High |
| 1.6–2.0 m | VNA trucks (guided) | Maximum |
Purchase price is only one component of what equipment costs over a typical 7–10 year lifecycle — energy, maintenance, downtime, and infrastructure frequently add up to more than the initial outlay. Working out the total cost of ownership (TCO) gives a fairer comparison between options than purchase price alone.
Acquisition cost: Purchase price, financing charges, or lease payments.
Energy and fuel: Electricity, LPG, or diesel consumption based on projected operational hours.
Maintenance: Scheduled servicing, wear parts, and an allowance for unexpected repairs.
Operator costs: Training, certification, and productivity differences between equipment types.
Downtime impact: Lost productivity during repairs and the cost of backup equipment.
Infrastructure: Charging stations, fuel storage, and any ventilation modifications required.
Residual value: Expected resale or trade-in value at end of useful life.
How you acquire equipment matters as much as what you acquire. Each route suits a different operational profile.
New purchase offers full warranty cover, the latest safety and efficiency features, and maximum working life — at the highest capital cost. It suits core fleet equipment with predictable, long-term utilisation.
Used and refurbished equipment can cut acquisition cost substantially, often by half or more against new list price, and is well suited to secondary duties, lower-hours applications, or businesses building a fleet on a constrained budget. Buy from an established dealer, ask for service history and hours, and confirm the machine comes with its latest statutory inspection record (a LOLER Thorough Examination report in the UK).
Before buying a used truck, check:
Contract hire (long-term) bundles the equipment, maintenance, and often the statutory inspections into a fixed monthly cost over a 3–7 year term. It transfers maintenance risk to the provider, keeps capital free, and makes budgeting predictable — at the cost of total spend typically exceeding outright purchase over the same period.
Short-term rental covers seasonal peaks, breakdown cover, one-off projects, and trial periods before committing to purchase. Rates are higher per week, but there is no long-term commitment.
PRO TIP: Hire and lease are particularly attractive when volumes are seasonal, technology is evolving quickly, or preserving capital is a priority. Always compare routes on a TCO basis, and review tax allowances and relief options with your accountant — the treatment differs significantly between purchase, hire purchase, and rental, and from country to country.
Safety considerations extend well beyond regulatory compliance. Well-designed equipment reduces incidents, improves operator retention, and lowers insurance costs. Comfort and ergonomics also have a direct bearing on productivity and staff turnover.
Safety law for using equipment at work is set country by country, so the detail depends on where the equipment will be used. The main points for the European Union and the UK are below; your dealer or your national workplace safety authority can confirm what applies to your site.
Across the EU: the Work Equipment Directive 2009/104/EC sets the minimum rules every employer must follow when using work equipment, including periodic inspection by a competent person and a record of the results. Each member state builds its own law on top of it and decides how often inspections are needed and how operators are trained and authorised. For example:
New machinery in the EU must meet the Machinery Directive 2006/42/EC and carry CE marking. From 20 January 2027 the Machinery Regulation (EU) 2023/1230 replaces the Directive; machinery placed on the market under the Directive before that date can still be sold afterwards. Used trucks already in service in the EU are not affected, but a second-hand machine imported from outside the EU, including from the UK, is treated as new to the EU market and must meet EU machinery rules.
In the UK: employers must comply with PUWER (Provision and Use of Work Equipment Regulations 1998), which covers the suitability, maintenance, and inspection of all work equipment. LOLER (Lifting Operations and Lifting Equipment Regulations 1998) applies specifically to lifting equipment and requires that all lifting operations are properly planned, supervised, and carried out safely. Thorough Examinations under LOLER must be carried out by a competent person — at least every 12 months for most lifting equipment, and at least every 6 months for equipment that lifts people and for lifting accessories, unless an examination scheme specifies otherwise. The HSE's Approved Code of Practice L117 provides authoritative guidance on rider-operated lift trucks, covering operator training, workplace organisation, and safe systems of work. New machinery supplied in Great Britain carries UKCA or CE marking (CE is accepted indefinitely); in Northern Ireland it must carry CE marking, as UKCA alone is not accepted.
Sources: Work Equipment Directive 2009/104/EC; Machinery Regulation (EU) 2023/1230; DGUV Vorschrift 68 (Germany); INRS: autorisation de conduite (France); LOLER regulation 9; HSE L117; GOV.UK: Supply of Machinery (Safety) Regulations 2008.
Used equipment often crosses borders, and many of the trucks listed on forktrucks.com are held by UK dealers. A truck moving between Great Britain and the EU is an import: allow for customs declarations, import VAT and possibly duty, and ask the dealer what paperwork and delivery they can arrange. Check that the machine carries the marking required where it will be used, that it comes with its latest inspection record, and that the operator's manual and safety labels are available in the language your operators need.
Active safety: Proximity sensors, automatic speed reduction, collision avoidance systems.
Passive safety: Seat belts, overhead guards, stability systems, blue safety lights.
Operator ergonomics: Adjustable seats, suspension systems, intuitive controls, climate control.
Visibility aids: Cameras, mirrors, clear sight lines, warning lights and alarms.
Telematics: Real-time monitoring of operator behaviour, impact detection, usage patterns, and predictive maintenance alerts.
Ensure your training programme covers equipment-specific operation, workplace hazard awareness, and refresher training in line with the rules where you operate. Lift truck operators must be trained and assessed as competent for the specific equipment and workplace, and in some countries, including Germany and France, the employer must also formally authorise each driver. In the UK, operators should be trained to the standards in L117, whether by in-house trainers or an external provider. There is no legal requirement to issue a certificate of basic training, but a certificate provides evidence that the operator has been trained. Accreditation of training providers is voluntary and can help you choose a provider that trains to a good standard; accrediting bodies include the members of the Accrediting Bodies Association: RTITB, AITT, ITSSAR, NPORS and Lantra. Many suppliers offer training packages as part of purchase or lease agreements — factor this into your supplier evaluation.
Equipment decisions should account for projected growth and evolving operational requirements over a 3–5 year planning horizon. Replacing equipment that no longer fits your operation is far more expensive than specifying correctly in the first place.
PRO TIP: Where uncertainty is high, consider hire, leasing, or modular equipment platforms that can be reconfigured as requirements evolve.
Work with established suppliers who can provide ongoing support, parts availability, and technical expertise throughout the equipment lifecycle. The quality of the supplier relationship often matters as much as the equipment specification itself.
To reach suitable suppliers in one step, use our Request a Quote form. It goes only to member dealers covering the make and the location where the equipment will be used, and there is a separate parts and ancillary equipment quote form for everything from batteries and chargers to tyres. If the equipment will be used elsewhere in Europe, start from our Europe quote page and choose your country.
Before finalising any equipment purchase, confirm that each of the following items has been addressed.
The right equipment comes from hard data about your loads and site, an honest comparison of running costs rather than purchase prices, and a supplier who will support it. Work through the eight steps and the checklist above before you commit.
No guide can replace site-specific expertise. For complex operations or significant investments, ask a materials handling specialist to assess your site and recommend equipment for it.
Last reviewed: September 2026.
If you can't find a supplier that meets your requirements, please request a quote from our members and they will get back to you.
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