Pallet Jack vs. Stacker - Key Differences Explained

Efficient material handling equipment is the backbone of any warehouse operation. Whether you're moving pallets short distances or storing them in high-density racks, choosing the right tool—pallet jacks, stackers, or stacker cranes—can make all the difference in productivity and cost savings.

This guide breaks down the key differences between pallet jacks and stackers, including automated stacker cranes for pallets, helping you decide which solution fits your warehouse needs.

2. What is a Pallet Jack?

2.1 Definition & Basic Function

A pallet jack (or pallet truck) is a simple, cost-effective tool designed to lift and transport pallets over short distances.

• Manual pallet jacks require physical effort to operate.

• Electric pallet jacks use battery-powered motors for easier handling.

• Load capacity: Typically 2,200 – 5,500 lbs.

• Lift height: Up to 8 inches (just enough to move pallets).

2.2 Common Uses

✔ Loading/unloading trucks
✔ Short-distance horizontal transport (e.g., from docks to storage)
✔ Retail stores & small warehouses

2.3 Pros & Cons

Pros:

• Affordable (low upfront cost)

• Easy to operate (minimal training required)

• Highly maneuverable in tight spaces

Cons:

• Limited lift height (cannot stack pallets)

• Manual effort required (for non-electric models)

3. What is a Stacker?

3.1 Definition & Types

A stacker is designed for lifting and stacking pallets at medium heights. The two main types are:

1. Walk-behind stackers – Operator guides the machine on foot.

2. Rider stackers – Operator rides the equipment like a forklift.

Stacker Cranes for Pallets (Automated Storage Systems)

A pallet stacker crane is a fully automated system used in Automated Storage & Retrieval Systems (AS/RS). These warehouse stacker cranes retrieve and store pallets in high-density racks without manual intervention.

3.2 How Stacker Cranes Work

• Operate in narrow aisles, maximizing storage space.

• Controlled by Warehouse Management Systems (WMS).

• Ideal for high-volume, high-density pallet storage.

3.3 Common Uses

✔ Multi-level pallet storage
✔ Cold storage & food distribution centers
✔ Large warehouses with AS/RS integration

4. Pallet Jack vs. Stacker: Key Differences (Comparison Table)

5. When to Use a Pallet Jack

✔ Small warehouses with basic transport needs.
✔ Retail & grocery stores moving pallets short distances.
✔ Operations with limited vertical storage requirements.

6. When to Use a Stacker or Stacker Crane

6.1 Standard Stackers

✔ Low-to-mid level stacking (up to 20 feet).
✔ Warehouses needing occasional vertical storage.

6.2 Stacker Cranes for Pallets

✔ High-volume distribution centers.
✔ Automated warehouses with AS/RS.
✔ Cold storage facilities requiring unmanned operations.

7. Safety Considerations

• Pallet Jacks: Basic OSHA training required.

• Stackers: Operator certification recommended.

• Stacker Cranes: Advanced training & system integration needed.

8. Future Trends in Pallet Handling

• AI-powered stacker cranes for optimized storage.

• IoT sensors for predictive maintenance.

• Hybrid systems combining manual & automated handling.

9. Frequently Asked Questions (FAQ)

Q: Can a stacker crane replace forklifts?
A: In high-density warehouses, yes—but forklifts are still better for versatile lifting.

Q: What's the maximum weight for a pallet jack?
A: Typically 5,500 lbs, but heavy-duty models handle more.

Q: Are stacker cranes worth the investment?
A: For large-scale operations, absolutely—they cut labor costs & maximize space.

10. Conclusion

Choosing between a pallet jack, stacker, or stacker crane depends on your needs:

• Pallet Jacks = Best for basic horizontal movement.

• Stackers = Ideal for low-to-medium stacking.

• Stacker Cranes = Perfect for automated, high-density storage.

Need expert advice? Contact our material handling specialists for a consultation today!