In any warehouse, distribution centre, or industrial environment, space and efficiency are critical. That’s where stackers come in. These versatile machines are essential for lifting, transporting, and stacking heavy loads—especially pallets—helping businesses streamline operations and reduce manual labor. Whether you’re upgrading your warehouse or planning a new setup, exploring new pallet stackers is a smart move toward efficiency, safety, and smart space utilisation.
What Is a Stacker?
A stacker is a type of material handling equipment designed to lift and move pallets or heavy items vertically and horizontally. While forklifts may get the bulk of the attention in industrial operations, stackers often provide a more economical and practical solution for smaller warehouses or areas with restricted space.
They are ideal for loading and unloading trucks, moving items around a warehouse, and stacking goods on racks or shelving. Stackers bridge the gap between manual labour and large-scale machinery, making them indispensable for companies seeking agile, affordable solutions.
Types of Stackers
Stackers come in various forms to suit different operational needs. Each type has specific advantages and ideal use cases.
1. Manual Stackers
Manual stackers rely entirely on human power for both lifting and propulsion. Operators pump a hydraulic handle to lift the forks and push the stacker to move it.
Key Features:
- Hydraulic lifting system
- No battery or motor
- Cost-effective and low maintenance
Ideal For:
- Small warehouses
- Light-duty applications
- Short transport distances
2. Semi-Electric Stackers
These stackers use electric power for lifting but still require manual effort for moving the unit.
Key Features:
- Electric lift mechanism
- Manual propulsion
- Compact size and versatile use
Ideal For:
- Medium-duty applications
- Businesses seeking a balance between cost and productivity
- Warehouses with moderate movement requirements
3. Fully Electric Stackers
Fully electric stackers are motorised for both lifting and moving, offering the highest level of efficiency.
Key Features:
- Powered lift and drive
- Rechargeable battery system
- Ergonomic controls
Ideal For:
- High-volume operations
- Large warehouses
- Long-distance material transport
Advantages of Using Stackers
Stackers contribute to optimized warehouse operations in several important ways:
1. Efficient Use of Vertical Space
Stackers are built to lift loads high off the ground, enabling efficient use of vertical racking systems. This is especially valuable in urban settings or smaller facilities where floor space is limited.
2. Improved Operational Flow
By simplifying the transportation and stacking process, stackers help create a smoother, more organised material handling system. This minimizes delays and enhances productivity.
3. Cost-Effectiveness
Compared to forklifts, stackers are generally more affordable to purchase, operate, and maintain. They provide excellent ROI for businesses looking to upgrade from manual handling without the financial burden of heavy equipment.
4. Enhanced Safety
Modern stackers are designed with safety in mind. They reduce the physical strain on workers, lower the risk of injury, and include safety features like emergency stop buttons, speed controls, and overload protection.
Factors to Consider When Choosing a Stacker
Choosing the right stacker for your operations involves evaluating several factors:
1. Load Capacity
Determine the typical weight of the loads you’ll be handling. Manual stackers generally support up to 1,000 kg, while electric models can handle significantly more.
2. Lift Height
Consider the maximum height you need to lift your loads. Standard stackers can reach up to 3-4 meters, but higher-reach models are available for specialised needs.
3. Aisle Width
Check the minimum aisle width in your facility. Electric stackers often require more space to manoeuvre, while manual models can navigate tighter spaces.
4. Frequency of Use
If your stacker will be used constantly, a fully electric model is a better investment. For occasional or light use, a manual or semi-electric version might suffice.
5. Power Source and Battery Life
For electric models, battery capacity and charging requirements are crucial. Look for lithium-ion options for faster charging and longer lifespan.
6. Operator Skill Level
Ensure your team is trained to use the type of stacker you choose. Electric models typically require more operator familiarity.
Applications of Stackers Across Industries
Stackers are versatile and find use across multiple sectors:
Warehousing and Distribution
In busy warehouses, stackers are used to move goods quickly from receiving docks to storage racks and from storage to shipping areas.
Retail and Wholesale
Stackers help manage backroom inventory and restock shelves in large retail environments.
Manufacturing
In factories, stackers assist in material movement between production lines, reducing time and labor.
Food and Beverage
Stackers are often used in food storage areas where cleanliness, precision, and temperature control are important.
Pharmaceuticals
For pharmaceutical companies, stackers are used in sterile environments to move and stack sensitive materials safely and efficiently.
Safety Features of Modern Stackers
Today’s stackers are built with a variety of safety mechanisms:
- Emergency stop switch for immediate shutdown
- Speed control to prevent runaway equipment
- Overload protection that alerts or stops the lift if the load is too heavy
- Stability systems to reduce tipping risks
- Ergonomic handle design to reduce operator fatigue
Proper training and maintenance further enhance the safe operation of stackers.
Maintenance Tips for Longevity
Like any piece of industrial equipment, stackers require routine maintenance to perform effectively:
- Regular inspections for signs of wear and tear
- Lubrication of moving parts to prevent rust and friction damage
- Battery care (for electric models), including proper charging and water level checks
- Hydraulic fluid checks for manual models
- Brake testing to ensure stopping power is reliable
Adopting a scheduled maintenance plan can dramatically extend the life of your stacker and reduce downtime.
Comparing Stackers with Other Material Handling Equipment
While forklifts and pallet jacks have their place, stackers offer a unique set of advantages:
Feature | Stackers | Forklifts | Pallet Jacks |
Vertical Lift | Yes | Yes | No |
Power Options | Manual, Semi, Electric | Primarily Electric or Diesel | Manual or Electric |
Cost | Low to Moderate | High | Low |
Ideal Space | Tight or moderate | Larger, open | Very tight |
Operator Training Required | Minimal to Moderate | High | Minimal |
Safety | High | Moderate | High |
This comparison highlights why many businesses opt for stackers as an efficient middle ground.
Sustainability Considerations
Electric stackers support green logistics goals by reducing emissions and noise pollution. Lithium-ion batteries are also recyclable and more energy-efficient compared to traditional lead-acid versions. Choosing energy-efficient equipment helps reduce your carbon footprint and aligns your operations with modern environmental standards.
The Future of Stackers
Innovation in material handling continues to advance. Emerging features include:
- Smart sensors for obstacle detection and load stability
- Telematics for tracking usage and maintenance needs
- Integration with warehouse management systems (WMS)
- AI-driven diagnostics for predictive maintenance
As warehouses become more automated, expect stackers to incorporate even more intelligent technology for seamless integration and operation.
Why Choose New Pallet Stackers from Criterion South Africa
Criterion South Africa offers a wide range of new pallet stackers designed to meet the highest standards of durability, performance, and safety. Whether you need manual, semi-electric, or fully electric models, our equipment is suited to diverse industries and warehouse environments.
Our expert team is available to help you assess your facility’s needs, recommend the most suitable equipment, and provide ongoing support. We also offer robust after-sales service and access to parts, ensuring your operations continue smoothly long after your purchase.
Modern Material Handling Strategies
Stackers play a critical role in offering a flexible, efficient, and safe way to transport and store heavy loads – especially in confined or busy warehouse spaces. From manual to electric models, the right stacker can boost your operational flow, protect your staff, and maximise your space.
Whether you’re starting from scratch or upgrading an existing system, investing in new pallet stackers from Criterion South Africa ensures you’re equipped with the tools you need for success.