Warehouse Machines

Modern warehouses run on a variety of specialised machines designed to move, store, and retrieve goods efficiently. From simple manual pallet jacks to sophisticated automated systems, the right equipment makes the difference between a productive operation and one that struggles to keep up with demand.

This guide provides an overview of the machines commonly found in warehouses and distribution centres. Whether you are setting up a new facility, expanding operations, or looking to understand what equipment could improve your productivity, this overview covers the essential categories.

Pallet handling equipment

Pallets are the foundation of warehouse logistics. Most goods arrive on pallets, are stored on pallets, and ship out on pallets. Moving pallets efficiently requires the right equipment.

Manual pallet jacks

The workhorse of warehouse floors everywhere. A manual pallet jack uses hydraulic lift powered by pumping the handle. Simple, reliable, and inexpensive, these handle short-distance moves and general pallet handling where forklifts are overkill.

Capacity: 2,000-2,500 kg typically
Cost: $300-700 new
Best for: Short distances, occasional use, backup equipment

Electric pallet jacks

Electric pallet jacks add powered drive and lift. Walkies let the operator walk alongside while riders include a platform to stand on. They move faster than manual jacks and reduce operator fatigue.

Capacity: 2,000-3,500 kg
Cost: $4,000-20,000
Best for: Medium distances, frequent use, high volumes

Pallet stackers

Stackers combine pallet jack mobility with vertical lift capability. They can stack pallets on top of each other or place them on low shelving without needing a full forklift.

Lift height: Up to 3-5 metres
Cost: $3,000-15,000
Best for: Stacking, low-level racking, limited space

Forklifts

Forklifts remain essential for heavy lifting and reaching height. Different types suit different applications.

Counterbalance forklifts

The classic forklift design with weight in the rear to balance loads on front forks. Available in electric, propane, and diesel versions. Forklift types vary by power source and capacity.

Capacity: 1,500-5,000 kg typical, up to 50,000 kg for heavy duty
Lift height: Up to 6+ metres
Best for: General purpose, loading docks, outdoor areas

Reach trucks

Designed for narrow aisle racking. The forks extend forward on a reach mechanism, allowing the truck to work in tighter spaces than counterbalance forklifts.

Aisle width: 2.5-3 metres
Lift height: Up to 12+ metres
Best for: High-bay racking, space-constrained warehouses

Order pickers

The operator rides up with the forks to pick items from height. Essential for warehouses that pick individual items from pallet locations rather than moving whole pallets.

Lift height: Up to 10+ metres
Best for: Order fulfilment, piece picking from height

Turret trucks and VNA

Very Narrow Aisle (VNA) trucks work in aisles as tight as 1.5 metres. The forks rotate to place pallets without turning the truck. Maximum storage density.

Conveyor systems

Conveyors move goods continuously without requiring an operator for each movement. They are the backbone of high-volume operations.

Belt conveyors

Continuous belt carries items along a path. Common for moving boxes, packages, and loose items. Simple and reliable.

Roller conveyors

Series of rollers that items ride across. Can be gravity-powered (items roll downhill) or powered. Good for boxes and totes with flat bottoms.

Sortation systems

Conveyors with diverters that route items to different destinations. Barcode or RFID scanning identifies items, and automated diverters push them to the correct lane. Essential for order fulfilment and distribution.

Spiral and vertical conveyors

Move items between different levels. Spiral conveyors carry items up or down in a continuous spiral. Vertical lifts raise items between floors.

Storage and retrieval

Racking systems

While not machines themselves, racking systems work with machines. Selective racking allows direct access to each pallet. Drive-in racking lets forklifts enter lanes. Push-back and pallet flow racking use gravity.

Automated Storage and Retrieval Systems (AS/RS)

Automated cranes or shuttles that store and retrieve goods from high-density racking without human operators in the aisles. Computer-controlled for efficiency.

Types: Unit load (pallets), mini-load (totes), shuttle systems
Benefits: Maximum density, accuracy, reduced labour
Investment: Significant - typically $1M+ for substantial systems

Vertical lift modules (VLMs)

Enclosed systems with trays that move vertically. Press a button and the system brings the needed tray to an access window. Excellent for parts storage and retrieval.

Carousel systems

Horizontal or vertical carousels rotate shelves to bring items to the operator. Good for small parts and high-pick-rate items.

Loading and shipping

Dock equipment

Dock levellers: Bridge the gap between dock and trailer
Dock seals and shelters: Weather protection during loading
Trailer restraints: Secure trailers during loading

Stretch wrappers

Machines that wrap pallets with stretch film for stability during shipping. Turntable models spin the pallet while the film dispenses. Rotary arm models move the film around a stationary pallet.

Strapping machines

Apply plastic or steel strapping around boxes or pallets for securing loads.

Automation and robotics

Automated Guided Vehicles (AGVs)

Self-driving vehicles that follow fixed paths (magnetic tape, wires, painted lines). Move pallets and materials without operators. Established technology with predictable behaviour.

Autonomous Mobile Robots (AMRs)

Navigate dynamically using sensors and maps rather than fixed paths. More flexible than AGVs. Can work alongside humans and adapt to changing environments.

Robotic picking

Robotic arms that pick individual items. Improving rapidly with AI and vision systems but still developing for diverse product types.

Goods-to-person systems

Robots bring shelving units to stationary workers who pick items. Popular in e-commerce fulfilment. Reduces walking time dramatically.

Support equipment

Lift tables

Power lift tables raise loads to comfortable working height. Reduce bending and improve ergonomics at workstations.

Scissor lifts

Scissor lifts provide elevated platforms for maintenance, inventory, and overhead work.

Industrial scales

Floor scales, pallet jacks with scales, and bench scales for weighing goods during receiving, shipping, and inventory.

Carts and dollies

Simple but essential for moving items that do not require forklifts or pallet jacks.

Choosing warehouse machines

Selecting equipment depends on several factors:

Volume: High throughput justifies automation; low volume may need only basic equipment
Product type: Pallets, cases, individual items each need different handling
Space: Available floor space and ceiling height constrain options
Budget: Equipment costs range from hundreds to millions
Labour: Automation reduces labour needs but requires different skills
Flexibility: Some systems are fixed; others adapt to changes easily

Start with understanding your workflows. Where are the bottlenecks? What tasks consume the most time? What causes errors or damage? Equipment should solve specific problems, not just add technology for its own sake.