Different Types of Forklifts

Different Types of Forklifts

Meta description: Explore various forklift types for different applications. Choose the suitable model based on load, environment, and budget.

This article examines the various types of forklifts and factors to consider when selecting a suitable model for a given operation. Different forklift classes are designed for specific indoor or outdoor applications based on load requirements, operational environment, and facility constraints.

Choosing the most suitable forklift depends on evaluating these key elements to ensure efficient material handling and optimal return on investment over the equipment’s lifecycle.

Key Takeaways

• When selecting a forklift model, consider load weight, size, stability, and indoor vs. outdoor use.
• Narrow aisle, multi-directional, and telescopic forklifts enable efficient operation in tight spaces or for overhead lifting needs.
• Budget the total cost of ownership over the equipment’s lifetime, as electric forklifts often have lower operating costs versus diesel models.
• Specialized forklifts include side loaders for forklift truck loading/unloading, pallet jacks for short-distance transport, and walkie stackers for high-rise storage.
• Choosing the appropriately sized and featured warehouse forklift based on the specific material handling application maximizes productivity and reduces costs.

What Are Forklifts?

Forklifts, also called lift trucks, are powered industrial vehicles used to lift and transport materials over short distances in indoor and outdoor environments.

Common types include counterbalance forklifts, reach forklifts, order pickers, pallet jacks, electric forklifts, and rough terrain forklift trucks equipped with pneumatic or cushion tires for lifting heavy loads and operating in narrow aisles, tight spaces, warehouses, storage facilities, construction sites, and other job sites.

Different Types of Forklifts

Forklifts come in various types, each designed for specific tasks and environments. Here are some common types of forklifts:

1. Counterbalanced Forklifts

Counterbalanced forklifts are versatile powered industrial trucks that operate in narrow aisles and tight spaces commonly found in warehouses, storage facilities, and other indoor working environments.

Equipped with either internal combustion engines running on diesel fuel or electric motors, counterbalanced forklifts have the lifting capacity to handle most load requirements while offering better fuel efficiency and lower emissions than other forklift models.

These warehouse forklifts are also widely used in construction sites for transporting building materials and supplies.

2. Reach Forklifts

Reach forklifts are powered industrial trucks operating narrow aisle warehouses and storage facilities. Equipped with a telescoping boom or mast, they can lift loads to greater heights than standard counterbalanced forklifts.

Reach trucks are commonly used to pick loads from high warehouse racks or to load and unload trucks. Models available include electric reach forklifts, pneumatic tire reach trucks, and internal combustion engine reach forklifts suitable for lifting heavy loads and precise pallet picking in tight spaces.

3. Rough Terrain Forklifts

Rough terrain forklifts are durable, rugged, powered industrial trucks suitable for outdoor job sites and other demanding environments. Equipped with pneumatic or cushion tires and a higher ground clearance than standard lift trucks, these forklifts can navigate uneven, unpaved, and slippery surfaces.

Typical applications include construction, landscaping, quarrying, agriculture, and warehouses or storage yards that require an indoor-outdoor operation. Powered by diesel fuel or electric motors, rough terrain forklifts have the lifting capacity needed for heavy loads in all weather conditions and terrains.

4. Industrial Forklifts

Industrial forklifts are versatile powered industrial trucks in various manufacturing and production environments. These heavy-duty lift trucks are commonly equipped with pneumatic tires for stability when transporting heavy loads over rugged industrial terrain.

Available models include electric forklifts, internal combustion engine trucks running on diesel fuel, and specialized forklifts with attachments for lifting, rotating, or clamping loads. Industrial forklifts are suitable for smaller turning radii and tighter spaces compared to larger capacity forklifts required for heavier cargo.

5. Articulated Forklifts

Articulated forklifts are powered industrial trucks operating in highly narrow aisles and tight spaces. Often called “narrow aisle forklifts,” these lift trucks feature an articulated chassis that pivots in the middle, allowing for tighter turns than regular counterbalanced forklifts.

Equipped with electric motors or internal combustion engines, articulated forklifts are commonly used in automotive plants, food processing facilities, and warehouses with storage racks positioned closely together. Their smaller turning radius enables precise pallet picking and placement even in confined areas.

6. Rail-Mounted Forklifts

Rail-mounted forklifts are specialized powered industrial trucks designed to operate on overhead rails installed in industrial facilities like warehouses and manufacturing plants.

Equipped with wheels or tires that run along rails mounted to the ceiling or walls, these narrow aisle forklifts provide precise positioning and lifting capabilities for loading and unloading trucks, railcars, or production lines without taking up floor space.

Standard models include electric rail-mounted forklifts and pneumatic tire rail-mounted lift trucks suitable for transporting heavy loads on rails.

7. Very Narrow Aisle Forklifts

Very narrow aisle forklifts are specialized powered industrial trucks designed for highly tight spaces with aisle widths of just a few feet. Often categorized as “narrow aisle forklifts,” these lift trucks usually have side-shifting capabilities and multi-directional steering for precise maneuvering and lifting loads in confined warehouse racks and storage facilities.

Models available include electric forklifts with advanced navigation and lifting controls and pneumatic tire trucks suitable for transporting heavy loads in the smallest spaces.

Their specialized features allow efficient order picking and inventory management even in the most dense storage environments.

8. Electric Powered Forklifts

Electric forklifts are industrial trucks that run on electric motors powered by rechargeable batteries. They provide a clean, quiet operation for indoor environments like warehouses and manufacturing facilities.

Electric models are available as counterbalanced forklifts reach trucks, order pickers, and other types suitable for transporting heavy loads in narrow aisles and tight spaces. These forklifts provide lower emissions and do not produce toxic fumes, making them well-suited for food, beverage, and pharmaceutical facilities.

Equipped with pneumatic tires or cushion tires, electric forklifts are easy to maintain and help lower operating costs compared to internal combustion engine trucks.

9. Multi-Directional Forklifts

Multi-directional forklifts are powered industrial trucks designed for extremely tight spaces, able to move and steer in any direction. These specialized lift trucks, also called multi-directional forklifts, are often used in narrow aisle warehouses and storage facilities with racking positioned closely together.

Equipped with electric motors or internal combustion engines, multi-directional forklifts feature side-shifting capabilities and 360-degree steering to precisely maneuver in tight quarters and pick loads from any position.

Their highly maneuverable design enables efficient order picking and transport of heavy pallet loads even in the most densely packed industrial environments.

10. Side Loader Forklifts

Side loader forklifts are powered industrial trucks designed for loading and unloading trucks on the side. Equipped with pneumatic tires for stability, these specialized forklifts feature a horizontal lifting mechanism to slide pallets onto and off transport vehicles efficiently.

Common models include electric side loader forklifts suitable for indoor use in narrow dock areas and diesel fuel side loaders capable of handling heavy pallet loads outdoors.

Their versatile side-shifting capability makes side-loader forklifts well-suited for distribution centers and cross-dock operations requiring efficient lift truck loading and unloading.

11. Telescopic Handler Forklifts

Telescopic handler forklifts are versatile powered industrial trucks featuring an extendable telescopic boom and fork attachment for lifting and transporting various loads. Equipped with pneumatic tires for stability while lifting heavy loads, these forklifts allow operators to lift and reach greater heights than standard lift trucks through their telescoping boom design.

Common models include diesel fuel telescopic handlers suitable for outdoor construction sites and electric versions for indoor use handling loads in tight spaces.

With their ability to lift at an elevation and extend horizontally, telescopic handler forklifts are especially useful for loading trucks, stocking high shelves, and construction applications requiring vertical and overhead reach.

12. Pallet Jack Forklifts

Pallet jack forklifts are small, manually operated powered industrial trucks designed to lift and transport loaded pallets short distances within facilities. Often called “pallet jack trucks,” these compact lift trucks feature a pallet fork attachment, an electric motor or an internal combustion engine, and pneumatic tires or cushion tires for rolling loads weighing up to 2 tons.

Commonly used in retail warehouses and distribution centers, pallet jack forklifts enable efficient movement of pallets during storage and order picking.

Their maneuverability in tight spaces complements larger electric forklifts and lift trucks transporting heavier palletized cargo over longer ranges.

13. Walkie Stacker Forklifts

Walkie stacker forklifts are powered industrial trucks designed for vertical lifting and storage of loads in racking systems. Often categorized as “walkie stackers,” these specialized lift trucks feature a hydraulic lifting mechanism and pneumatic tires for transporting loads at an elevation.

Commonly used in high-rise warehouses, walkie stackers allow operators to walk with loads lifted high above the floor level for precise placement in racking.

Models may be electric-powered or run on diesel fuel. They are suitable for transporting heavy palletized cargo to the uppermost storage racks. Their lifting capability enables efficient inventory management in facilities, maximizing ceiling height utilization.

Choosing the Right Forklift Type

Selecting the appropriate forklift model depends on a facility’s specific material handling needs. Considerations include:

Factors to consider for type of work

• Type of loads. Consider the weight, size, and stability of lifting and transporting loads.
• For indoor or outdoor use, forklifts must withstand weather elements and rugged terrain, while indoor models operate in controlled environments.
• Floor/ground surface conditions. Forklifts with pneumatic or cushion tires perform best on hard, level surfaces, whereas rough terrain trucks perform best on soft, uneven ground.
• Aisle widths. Narrow and very narrow aisles and multidirectional forklifts enable efficient operation between storage racks and facility structures in tight spaces.
• Lifting height and reach required. Telescopic handlers or walkie stackers may be needed for overhead placement of loads on high racks versus standard lift trucks.
• Attachment or accessory needs. Specialized forklifts support rotating, lifting, or clamping of loads for specific manufacturing or assembly applications.

Load Capacity and Size Requirements

The weight, dimensions, and stability of loads are essential when selecting a forklift. Heavy pallet loads may require a large-capacity forklift with pneumatic tires and an internal combustion engine. Meanwhile, an electric forklift or pallet jack could serve more minor and frequent lifting needs.

Forklift models rated for Class V-VII have higher lifting capacities for transporting heavier cargo. Operators should also assess load sizes and ensure the forklift’s rack dimensions and fork length can accommodate the loads.

Indoor vs Outdoor Operations

Forklifts designed for indoor use have features that make them suitable for controlled warehouse and plant environments. Models like electric forklifts are quieter and produce fewer emissions, which is ideal for enclosed spaces.

Outdoor forklifts feature hardier designs like diesel fuel engines and rugged tires capable of withstanding weather elements at construction sites and rough terrain.

Outdoor models may also offer greater lift capacities for transporting heavy loads over long distances in all conditions. The operational environment should guide the selection of an indoor forklift or rough terrain forklift as needed.

Budget

Budget is an essential factor to consider when selecting a forklift. Upfront costs should be evaluated, including the purchase price and ongoing expenses like maintenance and fuel. Electric forklifts typically have lower operating costs compared to diesel or gasoline-powered models.

Less expensive options include pallet jacks or manual pallet trucks for lightweight lifting needs. However, selecting a forklift based only on price could result in higher total costs if it lacks the capacity, features, or durability required by the operation. Value over lifecycle must be weighed against initial investment.