Double Pallet Jacks

Double pallet jacks—also called tandem pallet jacks or dual pallet trucks—feature extended forks designed to handle two standard pallets simultaneously. For operations moving high volumes of palletized goods, these specialized units can dramatically improve throughput by cutting the number of trips in half.

While standard pallet jacks handle one pallet at a time, double pallet jacks extend this capability for operations where efficiency gains justify the specialized equipment. From trailer loading to warehouse transfers, understanding when and how to deploy double pallet handling pays dividends in productivity.

This guide covers double pallet jack types, specifications, applications, and practical considerations for implementing dual pallet handling in your operation.

What is a double pallet jack

Double pallet jacks are pallet trucks with forks long enough to carry two standard pallets placed end-to-end. They come in both manual and powered versions.

Key characteristics

Fork length. Typically 2,400-2,700 mm (96-108 inches) to accommodate two 48-inch pallets.
Capacity. Usually 4,000-5,000 kg (8,800-11,000 lb) to handle two loaded pallets.
Width. Standard pallet jack width, fitting between pallet racking.
Power. Available in manual (hand pump) and electric versions.

How they differ from standard units

Feature	Standard Pallet Jack	Double Pallet Jack
Fork length	1,000-1,220 mm (40-48")	2,400-2,700 mm (96-108")
Pallet capacity	One pallet	Two pallets
Weight capacity	2,000-2,500 kg	4,000-5,000+ kg
Overall length	~1,500 mm	~3,000 mm
Maneuverability	Standard	Reduced (longer turning)
Price	$300-700 manual	$600-1,500+ manual

Types of double pallet jacks

Manual double pallet jacks

Hand-pump operated units for lighter duty double pallet handling.

Capacity. Typically 4,000-5,000 kg (8,800-11,000 lb).
Operation. Standard pump handle for lifting; manual pushing/pulling.
Best for. Short distances, occasional use, budget-conscious operations.
Limitation. Physically demanding with heavy loads over distance.
Price range. $600-1,500.

Electric double pallet jacks

Powered walkies designed for two-pallet handling.

Capacity. 4,000-6,000+ kg (8,800-13,200+ lb).
Operation. Electric drive and lift; operator walks alongside.
Best for. High volume, longer distances, frequent use.
Features. Variable speed, regenerative braking, programmable settings.
Price range. $6,000-15,000+.

Rider double pallet trucks

For maximum productivity over longer distances.

Capacity. 4,000-8,000 kg (8,800-17,600 lb).
Operation. Operator rides on platform.
Speed. Up to 12 km/h (7.5 mph).
Best for. Long horizontal transport, distribution centers.
Price range. $12,000-25,000+.

Quad pallet trucks

Some operations use extra-long units for handling four pallets:

Fork length. 4,800+ mm (192+ inches).
Application. Specialized trailer loading operations.
Rarity. Uncommon; very specific use cases.

Specifications

Manual double pallet jack specifications

Specification	Typical Values
Load capacity	4,000-5,000 kg (8,800-11,000 lb)
Fork length	2,400-2,700 mm (96-108 in)
Fork width (outside)	540-685 mm (21-27 in)
Lowered fork height	75-85 mm (3-3.3 in)
Raised fork height	190-205 mm (7.5-8 in)
Overall length	2,800-3,100 mm (110-122 in)
Steering wheel diameter	180-200 mm (7-8 in)
Load wheels	Tandem (4 per fork) typical
Unit weight	110-150 kg (242-330 lb)

Electric double pallet jack specifications

Specification	Typical Values
Load capacity	4,000-6,000 kg (8,800-13,200 lb)
Fork length	2,400-2,700 mm (96-108 in)
Travel speed (loaded)	5-6 km/h (3-3.7 mph)
Lift speed (loaded)	0.03-0.04 m/s
Battery voltage	24V
Battery capacity	375-620 Ah typical
Gradeability (loaded)	3-5%

Applications

Trailer loading and unloading

The primary application for double pallet jacks:

Load two pallets per trip into trailers
Cut loading/unloading time nearly in half
Particularly effective for floor-loaded trailers
Reduces dock door congestion with faster turns

Warehouse transfers

Moving pallets between zones
Staging areas to shipping docks
Receiving to storage locations
Any operation with repetitive two-pallet moves

Cross-docking

High-speed product flow through facility
Inbound to outbound with minimal storage
Time-sensitive distribution operations

Manufacturing

Moving materials between production stages
Finished goods to shipping
Raw materials to production lines

Cold storage

Double pallet handling is especially valuable in freezers where:

Operators want to minimize time in cold
Door openings should be reduced
Efficiency gains multiply in harsh conditions

Benefits

Productivity gains

Fewer trips. Move twice the product per trip.
Faster loading. Trailer loading time reduced 30-50%.
Less travel. Reduced total distance traveled per shift.
Higher throughput. More pallets moved per hour per operator.

Operational efficiency

Dock door utilization. Faster truck turns free doors sooner.
Labor efficiency. More product moved per labor hour.
Reduced congestion. Fewer pieces of equipment in aisles.
Driver wait time. Faster loading reduces detention charges.

Cost savings

Lower labor cost per pallet moved
Reduced equipment quantity needed
Less wear on equipment (fewer cycles)
Lower energy consumption (electric units)

Considerations and limitations

Space requirements

Turning radius. Longer forks require more space to maneuver.
Aisle width. Need wider aisles than standard pallet jacks.
Staging areas. More space needed to align two pallets.

Load handling

Both pallets must go same direction. Can't split easily.
Pallet alignment. Pallets must be aligned end-to-end.
Weight distribution. Uneven loads affect handling.
Pallet condition. Both pallets must be in good condition.

Physical demands (manual units)

Starting effort. Higher rolling resistance with double weight.
Steering effort. More force needed to steer heavy loads.
Operator fatigue. Manual double pallet jacks more tiring.
Recommendation. Electric units preferred for regular high-volume use.

Cost considerations

Higher equipment cost. 50-100% more than standard units.
Specialized use. May not replace standard units for all tasks.
ROI analysis. Benefits must justify investment.

Selecting a double pallet jack

Key questions

How many two-pallet moves per day?
What's the average load weight?
What distance between pickup and drop?
What's the floor condition (smooth, joints, dock plates)?
How wide are your aisles and maneuvering areas?
Manual operation feasible or electric required?

Manual vs. electric decision

Factor	Choose Manual	Choose Electric
Moves per day	Under 20-30	Over 30
Average distance	Under 30m (100ft)	Over 30m (100ft)
Average load	Under 2,000 kg	Over 2,000 kg regular
Budget	Limited	Adequate for ROI
Operator stamina	Occasional use OK	Regular use—reduce fatigue

Capacity selection

Calculate maximum load: heaviest pallet × 2 + safety margin
Consider pallet weight variation
Account for uneven load distribution
Select capacity 20% above typical maximum

Operating tips

Loading two pallets

Align pallets end-to-end before approaching
Enter first pallet fully before pumping up
Continue into second pallet
Lift both pallets simultaneously
Verify both pallets are properly seated

Maneuvering

Plan route before moving—avoid tight turns
Watch tail swing when turning (rear extends wide)
Take corners slowly and deliberately
Pull loads when possible for better visibility

Trailer loading

Square up with trailer door before entry
Watch for trailer movement on entry (not properly chocked)
Account for dock plate transition
Position systematically for efficient trailer use

Safety considerations

Never exceed rated capacity
Check pallet condition before handling
Secure unstable loads before moving
Watch for pedestrians—longer unit harder to see around
Take extra care on ramps and slopes

Maintenance

Double pallet jacks require similar maintenance to standard units with attention to:

Load wheels. Four or more load wheels wear faster under double loads.
Fork condition. Longer forks more susceptible to bending—inspect regularly.
Hydraulic system. Higher loads mean more pump cycles and seal wear.
Lubrication. More pivot points on longer forks need attention.

For complete maintenance guidance, see our pallet jack maintenance guide.

Pricing

Type	Price Range
Manual double pallet jack	$600-1,500
Electric walkie double	$6,000-15,000
Electric rider double	$12,000-25,000+