Forklifts remain essential tools for modern-day material handling activities, enabling the efficient movement of goods across a wide variety of environments including warehouses, construction sites, ports, and manufacturing facilities. Selecting the right type of forklift is critical to ensuring operational efficiency, safety, and cost-effectiveness. Each forklift type is designed with specific tasks in mind, and understanding their unique features and applications can help businesses make informed decisions. Our latest article explores features, common applications, and safety considerations for each type of forklift truck.
Understanding Forklift Classifications
Forklifts are classified based on their design, functionality, and intended use. These classifications help businesses choose the right equipment for their specific operational needs, ensuring efficiency, safety, and cost-effectiveness. Below is an overview of forklift classifications, highlighting the importance of matching the right type to your operational requirements.
Forklift Classifications
The classification of forklifts is typically defined by their design and application. Common classifications include:
- Class I: Electric Motor Rider Trucks – powered by electric batteries, they are ideal for indoor use with a smooth surface, such as warehouses and retail settings.
- Class II: Electric Motor Narrow Aisle Trucks – designed for narrow aisle operations, they maximise the available storage space in confined areas and include order pickers and reach trucks.
- Class III: Electric Motor Hand or Hand-Rider Trucks – these types of forklift trucks are compact and operated manually or with a platform for a manual worker. They are ideally suited for moving pallets over short distances.
- Class IV: Internal Combustion Engine Trucks (Solid Cushion Tyres) – similar to VNAs these are suitable for indoor use on smooth surfaces, and are typically powered by gas or diesel engines.
- Class V: Internal Combustion Engine Trucks (Pneumatic Tyres) – equipped with pneumatic tyres for enhanced traction, they are designed for use outdoors on uneven surfaces.
- Class VI: Electric and Internal Combustion Engine Tow Tractors – used for towing as opposed to lifting, they are commonly seen in manufacturing and airport operations.
- Class VII: Rough Terrain Forklifts – designed for outdoor environments with rugged surfaces, they are suited to construction sites and agricultural fields.
Importance of Matching Forklift Type to Operational Needs
Understanding the forklift classification is important when choosing the right forklift type to ensure operations are optimised using the most appropriate material handling equipment. It is also critical for optimising operations and ensuring workplace safety. Here’s why:
- Operational Efficiency – choosing a forklift suited to specific handling tasks reduces time and increases productivity.
- Cost-Effectiveness – using the appropriate forklift truck minimises wear and tear, reducing maintenance costs over time.
- Safety Compliance – matching the forklift truck to the specific work environment and load type required for handling, reduces the risk of accidents.
- Adaptability to Environment – indoor forklifts with solid tyres are suitable for smooth floors whereas facilities with uneven ground such as construction sites, are better suited to rough terrain forklifts.
- Regulatory Compliance – certain industries have specific regulatory requirements for equipment use, such as emissions for indoor forklift trucks.
Different Types Of Forklifts
Understanding forklift classifications helps you to align your forklift choice with your operational needs. This enables you to enhance productivity, ensure the safety of workers, goods, and building infrastructure, and reduce costs. It’s also important to consider factors such as the working environment, load requirements, and specific tasks required for your operations when selecting your equipment.
1. Counterbalance Forklifts
Counterbalance forklifts are among the most common types used in warehouses and industrial settings. They come as a standard design with dual forks on the front, and feature a weight at the back to counteract the load lifted by the forks. Models are available in electric, gas, and diesel-powered, offering a versatile solution to materials handling with easy operation and a balanced load capacity. They are ideal for general warehouse and factory loading and unloading tasks and can be used indoors or outdoors. Attention should be paid to ensuring that ground conditions are stable and operators avoid overloading the forks to prevent tipping. Often in high-volume usage, regular maintenance is important to ensure operations are not impacted by poor driving or excessive wear and tear.
2. Low-Level Order Picks (LLOPs) & Powered Pallet Trucks
Low-level order picking trucks are designed for retrieving items from lower shelf levels in warehouses. They have a compact design which allows for excellent manoeuvrability for low-height lifting, and they are electrically powered for enhanced efficiency. LLOPs are ideally suited to e-commerce and retail distribution centres for stock replenishment and transporting goods over short distances. To ensure safe usage, operators should receive proper training, avoid excessive speeds, especially in compact areas, and regularly check controls and batteries.
Powered pallet trucks, also known as pallet jacks, are primarily used for moving palletised loads over short distances. They are relatively small in size with low lifting capabilities and have an electric-powered operation with a simple control system making them ideal for general warehouse tasks. They are ideally suited to loading and unloading from delivery trucks, retail restocking, and transporting goods around the warehouse facility. Users should be aware of overloading the pallet truck, regularly inspect for wear and tear, and ensure clear pathways to prevent collisions or damage to stock and building infrastructure.
3. High-Level Order Pickers (HLOPs) & VNA Trucks
High-level order-picking trucks are used to access items stored on upper shelves in warehouses. They feature an operator platform providing direct access to goods, capable of reaching heights exceeding 30 feet. Working at this level means HLOPs are equipped with additional features such as harnesses and guardrails to keep workers safe when picking at height. They are commonly used in warehouses and distribution centres with high racking structures for either order-picking tasks or inventory management. HLOPs can be either free roaming or guided using rail or wire guidance. To maintain safety levels, operators must be trained and certified, and should conduct regular maintenance checks of all HLOP forklifts.
Very Narrow Aisle (VNA) trucks are designed to operate in tight spaces allowing them to optimise storage and replenishment tasks in warehouses with narrow aisles. VNAs feature a slim design with advanced steering systems suited to navigating narrow aisles and have significant reach capabilities making them effective and highly efficient at order-picking tasks. They are adept at maximising warehouse storage space and handling inventory in confined or compact areas and are always operated with fixed guidance via rail or wire systems to optimise operational efficiency and safety. VNAs should be operated in well-lit and clearly marked aisles using drivers who are trained in precision driving due to the narrow operating environment. Particular attention should be paid to the condition of the steering systems as these are vital for safe operation.
4. Reach Trucks
Reach trucks are a specialised form of forklift truck designed for high-reaching tasks in warehouses. They have an extended mast fitted to the forklift that can move loads deep into a racking structure. They feature a high lift height with narrow frame, offering an extended reach for accessing deep shelving or racking, and provide excellent visibility for operators. They are widely used for retrieving and replenishing pallets in tall aisles of racking and work efficiently in both ambient and cold storage facilities. Safety considerations include maintaining a stable load handling and operating at a safe speed to prevent tipping. Both masts and hydraulics should be inspected regularly.
5. Rough Terrain Forklifts
Rough terrain forklifts are designed for outdoor use and are particularly effective where the ground may be uneven or rugged. They feature a durable frame, large pneumatic tyres providing enhanced traction, and a powerful engine capable of handling heavy loads. Due to their robust design, rough terrain forklifts are commonly used on construction sites as well as in the agricultural and timber industries. With tough working conditions, managing terrain forklifts effectively should include avoiding steep inclines, and ensuring each load is properly secured. For maintenance, tyre conditions should be monitored and checked regularly.
6. Side loaders
Side loaders are specifically designed for handling long and bulky loads, such as timber or pipes. The forks are positioned on the side of the truck providing a high level of stability for long items and are capable of operating in narrow aisles given this setup. Side loaders are often used in lumber yards, steel mills, or manufacturing where long, heavy items require careful and precise lifting. When operating side loaders, drivers should be vigilant maintaining clear visibility. They should also take care to balance long loads exactly, to prevent tipping or allowing the item to slip. With pressure on accurate lifting, the lifting mechanisms should be checked frequently to ensure no wear and tear could impact its effectiveness.
7. Telehandlers
Telehandlers, also known as telescopic handlers, are highly versatile and combine the key features of both a forklift and a crane. They consist of an extendable boom designed to reach locations that are high up and have attachments such as buckets and winches to carry out various tasks. They also feature large tyres to provide efficiency for all-terrain use such as in the construction, ports, and agricultural industries. They are also used for loading pallets and materials onto rooftops or other high platforms. Due to their size, telehandlers can use additional stabilisers when lifting heavy loads and operators should receive training for complex tasks to avoid common issues such as overextending the boom.
Whether you need a forklift for tight warehouse aisles or rugged outdoor terrains, understanding these seven types, their features and most suitable applications, will help you make an informed decision.
Safety Considerations Across Different Forklift Types
From ports to construction sites and across warehouses and distribution centres, choosing the right forklift depends on the specific requirements of your operations. Regardless of the forklifts’ usage, it’s vital to always prioritise safety by ensuring proper training, regular equipment maintenance, and adherence to manufacturers’ operational guidelines.
In addition, technology solutions such as pedestrian and proximity warning systems, adaptive speed control, or power saver idle timeout to prevent excessive engine wear and tear, all offer an additional ‘safety net’ for forklift operation. Integrating advanced sensors and systems will further enhance any usage of forklift trucks, protecting the workforce and striking the right balance between safety and productivity.
Contact our team today to improve forklift safety. Speak to our friendly team by calling 0116 260 4200.