If you’ve ever managed a warehouse or stockroom, you know how vital it is to move and store pallets quickly, safely, and without wearing your team out. That’s exactly why electric stackers are becoming so popular. They help you lift, stack, and relocate pallets with minimal strain, and they’re smaller and more efficient than traditional forklifts.
But with so many types of stacker trucks on the market, it can be tough to figure out which one suits your needs. Below, I’ll walk you through what electric stackers are, why they’re worth considering, and the different variations available so you can make a confident choice for your business.
Table of Contents
What is an electric stacker?
How electric makes a difference
Why not petrol or diesel?
Why are electric stackers so useful?
They save time
They’re safer for workers
They help you use space more efficiently
They’re environmentally friendly
They can double as transportation
Finding the right stacker for your business
1. How large is your facility?
2. How heavy and how high?
3. How often will you use it?
4. What’s your budget?
The common types of electric stackers
1. Electric pallet stacker
2. Walkie stackers
3. Counterbalance stackers
4. Straddle stackers
5. Mono mast stacker
What to do before choosing an electric stacker
1. Map your warehouse
2. Consider growth plans
3. Look at the battery technology
Final takeaways
What is an electric stacker?
In simple terms, a stacker is a piece of equipment meant to lift and stack pallets. Many busy warehouses or retail spaces keep at least one stacker on-site because it’s more versatile than a pallet truck (which only lifts a few inches) and less cumbersome than a forklift (which can be overkill for smaller spaces).
How electric makes a difference
Unlike a manual or hydraulic pump stacker, an electric stacker is powered by a battery, so you don’t have to rely on arm strength to raise the load. Electric stackers also reduce the chance of injury, do the heavy lifting for you at the press of a button, and often handle heavier loads than manual alternatives.
Why not petrol or diesel?
Electric stackers have a lighter environmental footprint and generally lower running costs (no gasoline or diesel to buy). Lithium-ion (Li-ion) batteries have become very popular because they charge quickly, last longer, and don’t require the upkeep of older lead-acid models.
Why are electric stackers so useful?
As e-commerce grows, warehouses are getting larger and more filled with products stacked ever higher. It’s not uncommon to see pallets stacked up to 13 meters high, which is physically impossible to manage without powered equipment. Here are a few reasons electric stackers shine:
They save time
Electric lifting is speedy. You won’t spend forever pumping a handle to lift a pallet; you can move pallets around the facility in minutes rather than hours.
They’re safer for workers
Manual lifting or hydraulic pumping can lead to injuries (think back, shoulder, and spine injuries). Electric stackers eliminate that repetitive strain, significantly reducing the risk of musculoskeletal issues.
They help you use space more efficiently
Because they are typically more compact and nimble than forklifts, electric stackers can comfortably operate in narrow aisles or tightly packed storerooms.
They’re environmentally friendly
Electric stackers are a greener option because they do not rely on fossil fuels. Many models now use lithium-ion batteries, which are energy-efficient, low-maintenance, and quick to charge.
They can double as transportation
Some electric stackers include a small ride-on platform or carriage, letting the operator glide around larger warehouse spaces without walking—a real time-saver.
Finding the right stacker for your business
Before you jump into specific models, it’s helpful to nail down a few basics about your operation:
1. How large is your facility?
A tight, crowded warehouse might call for a smaller, more maneuverable model, while a large facility could benefit from a ride-on stacker that moves quickly across the floor.
2. How heavy and how high?
Consider the maximum weight of your pallets and think about the highest shelving or stacking point you need to reach. Electric stackers have different lift capacities and maximum heights, so you must pick one that matches your requirements.
3. How often will you use it?
If you use a stacker occasionally, you might not need a high-end, heavy-duty model. But if you’re running at full tilt, day in and day out, a robust machine (possibly with rapid-charging batteries) is worth the investment.
4. What’s your budget?
Electric stackers can be pricey, but long-term labor costs, maintenance, and reduced injury risk savings are worth the investment.
The common types of electric stackers
Electric stackers aren’t one-size-fits-all. Below are the main variations you’ll likely come across and why they might (or might not) be right for your situation.
1. Electric pallet stacker
An electric pallet stacker is the “standard” of this category. It can handle up to around 1,600 kg and lift pallets to around 4.8 meters, though exact specs vary. They are best for warehouses or storerooms where you need a reliable workhorse to handle typical-sized pallets.
- Benefits: They’re powered by lithium-ion batteries (in many modern models), which are easy to charge and more eco-friendly than traditional lead-acid. They also maneuver well in tighter spaces compared to forklifts.
2. Walkie stackers
“Walkie” means the operator walks alongside or behind the machine while guiding it. No ride-on platform here. They can easily handle light-to-medium workloads, especially in smaller or congested areas where you don’t want a big truck rolling around.
- Benefits: They can still lift high and carry significant weight. However, they’re typically simpler to learn and less expensive than ride-on versions because you walk behind them.
3. Counterbalance stackers
These have a built-in weight on one end to “counterbalance” the load. This design helps maintain stability without requiring the extra legs you might see on other stackers. Counterbalance stackers are great for small-to-medium loads in places where a full-size forklift can’t fit or where you only need to travel short distances.
- Benefits: It offers decent lift capacity in a more compact footprint, perfect if you don’t have an ample turning radius for a forklift.
4. Straddle stackers
Straddle legs slide around the base of a pallet (rather than in front of or behind it). This design is particularly stable and good for narrow pallets. They’re also a better option for narrow aisles or cramped warehouse layouts. Straddle stackers can also handle open and closed pallets with bottom runners.
- Benefits: Great maneuverability and typically more flexibility in terms of pallet types.
5. Mono mast stacker
This is a more lightweight variant of an electric stacker, typically with a single mast and a lower lift capacity (around 1,200 kg). Smaller businesses dealing with lighter goods will love this model. People often use them for head-height tasks, like picking items or loading pallets for inspection.
- Benefits: Slim and maneuverable in tight places but still powered, so you don’t have to strain to lift.
What to do before choosing an electric stacker
Electric stackers have many options, so what should you do to narrow the choices? Here’s what to check off your list:
1. Map your warehouse
Look at your aisles, doorways, and areas where people usually move around. A walkie-talkie stacker or single-mast stacker might be the better option if your space is small. But a bigger electric stacker will help you work faster if you have more room.
2. Consider growth plans
Will you add more products or heavier pallets in the future? If so, choosing a stacker that can handle more weight than you currently need is better.
3. Look at the battery technology
Lithium-ion batteries usually charge quicker and last longer than lead-acid options. So, if the team works several shifts, choosing batteries that charge quickly can save time and hassle.
Final takeaways
Electric stackers come in various shapes and sizes for a good reason: businesses and warehouses all have unique setups. No matter which kind you choose, the overarching theme is efficiency and safety. With an electric stacker on your team, you’ll move items faster, store products higher, and reduce the wear and tear on your workers.
Choosing the right electric stacker can improve the smoothness of your business, the safety of your employees, and the speed with which products are delivered. This investment often improves efficiency, productivity, and peace of mind.
