Pallet Jack Applications

A pallet jack is one of the most flexible tools in any material handling operation. It links many small steps in a supply chain from the moment a pallet leaves a truck through storage picking packing and final loading again.

This guide walks through the main applications of pallet jacks across industries. It shows how different designs manual electric high lift rough ground stainless and weighing pallet jacks support specific tasks.

Core roles of pallet jacks in logistics

Pallet jacks handle short distance moves at ground level. They fill the gap between manual lifting and forklifts. In many businesses they support almost every stage of the internal flow of goods.

Common core roles include

Unloading and loading trucks at docks and ground level
Moving pallets between receiving areas staging zones and storage
Feeding and clearing workstations and production lines
Handling order picking and packing in low level storage

Supporting inventory counts cycle checks and stock rotation
Moving returns damaged goods and waste pallets to inspection or disposal

In very small operations a good manual pallet jack can handle nearly all internal movement of palletised goods. In larger operations pallet jacks work beside forklifts conveyors and automated systems to cover the small moves between main steps.

Pallet jack applications in warehouses and distribution centres

Warehouses and distribution centres are the most common environments for pallet jacks. Applications differ slightly between manual and electric models.

Receiving and putaway

At inbound docks staff often use pallet jacks to

Move pallets from the truck bed to a staging area when there is no dock leveler or forklift available
Break down mixed pallets and move partial loads to specific zones
Transfer pallets from a dock area to the reach trucks or very narrow aisle trucks that complete putaway into racking

Manual pallet jacks handle light to medium weight pallets over short distances. Electric pallet jacks often take over when pallets are heavy travel distances are longer or throughput is high.

Order picking and replenishment

In many low and medium height warehouses pickers use pallet jacks as mobile bases for order assembly.

Typical uses are

Low level case picking from floor level or first beam locations
Building mixed pallets for store orders or customer shipments
Replenishing fast moving pick faces from reserve storage

Electric walkie pallet jacks are common in these tasks because they reduce strain from constant walking and pulling. Rider pallet trucks appear in big cross dock and retail distribution sites where pick routes are long.

Loading outbound trailers

For small and medium operations pallet jacks are often the main tool used inside outbound trucks.

Applications include

Positioning pallets in trailers after a forklift places them near the door
Shifting pallets to close gaps and optimise trailer space
Unloading partial returns from store trucks when full forklifts cannot enter

Low profile pallet jacks help when trailer floors are worn or dock plates sit slightly lower than ideal. Long fork pallet jacks can place two pallets deep into a trailer when the layout and load allow it.

Inventory checks and internal moves

Pallet jacks support many secondary jobs such as

Moving pallets for cycle counts and stock investigations
Rotating dated goods in food and pharma warehouses
Rearranging fast and slow movers during layout changes
Carrying tools spare parts and maintenance materials on pallets

In these roles durability and ease of steering matter more than absolute capacity.

Pallet jack applications in manufacturing

Manufacturing plants use pallet jacks to feed production and move work in progress between steps. They often work in tight spaces between machines where forklifts do not fit safely.

Key applications are

Delivering raw materials and components from stores to lines
Moving work in progress pallets between assembly welding or machining steps
Feeding packaging lines with empty cartons film and pallets
Removing finished goods from end of line equipment to wrapping and shipping

High lift scissor pallet jacks act as work positioners at assembly and packing stations. They raise pallets to a comfortable height so workers do not bend repeatedly.

In clean or high value production such as electronics or medical devices pallet jacks with special wheels and low marking materials reduce contamination and floor damage.

Pallet jack applications in retail and wholesale

Retail and wholesale operations rely on pallet jacks in back rooms on shop floors and in small delivery vehicles.

Back room uses include

Unloading store deliveries when no forklift is on site
Moving pallets of mixed merchandise to staging points for shelf filling
Handling empty pallets and waste packaging to compactors or returns cages

On the sales floor low noise pallet jacks with quiet wheels move display pallets in early morning and late night hours without disturbing customers or neighbours. Narrow and short pallet jacks help in aisles where turning space is limited.

Cash and carry and wholesale clubs often move full display pallets around the sales area with electric pallet jacks for fast reset of promotional zones.

Pallet jack applications in food cold chain and hygiene sensitive sites

Food distribution and processing impose special demands on equipment. Pallet jacks here need specific materials and features.

Common applications are

Moving chilled and frozen goods in cold stores
Handling ingredients and packaging in food factories
Serving clean rooms and packing lines in dairy meat and bakery plants
Supporting quick loading at night for supermarket and restaurant deliveries

Stainless steel and galvanised pallet jacks resist corrosion from washdowns and cleaning chemicals. Closed fork designs and smooth welds reduce places where dirt and bacteria can build up.

In cold stores pallet jacks need low temperature hydraulic oil and plastics that stay tough at low temperatures. Polyurethane or rubber wheels keep better grip on cold damp floors than very hard materials.

Pallet jack applications in logistics yards construction and outdoor sites

Standard pallet jacks struggle on rough outdoor ground. For these locations rough ground or all terrain pallet jacks use big pneumatic or deep tread wheels and more ground clearance.

Typical outdoor applications include

Moving building materials across yards and partially finished slabs
Handling palletised soil plants and stone in garden centres
Moving agricultural supplies around farm yards barns and open sheds
Carrying event equipment across grass gravel and compacted soil

In many of these jobs all terrain pallet jacks complement rough terrain forklifts. Forklifts handle long moves and truck loading. All terrain pallet jacks cover last metre moves into tight corners under roofs and inside temporary structures.

Pallet jack applications in transport and last mile delivery

Pallet jacks are vital tools in trucks and small vehicles that use tail lifts or ramp loading.

Key applications are

Moving pallets inside box trucks between tail lift and front bulkhead
Handling palletised parcels and mixed freight in less than truckload operations
Delivering heavy goods such as drinks kegs tiles and building materials to customers
Serving urban deliveries where forklifts cannot enter streets or courtyards

Drivers often carry compact or short pallet jacks on vehicles so they can unload pallets from tail lifts and position them just inside customer premises.

Special pallet jack designs for specific applications

Different pallet jack variants exist to serve specialised tasks. Choosing the right type makes a big difference to efficiency and safety.

Low profile pallet jacks

Low profile pallet jacks have reduced fork height to enter pallets with low openings or damaged boards. They are common in import export logistics and recycling where pallets are reused many times and may deviate from standard dimensions.

High lift and scissor pallet jacks

High lift pallet jacks raise loads much higher than standard trucks. They act as simple lift tables at workstations and are used in

Packing and kitting stations where staff work directly from pallets
Light assembly operations where components must sit near hand level
Quality inspection and rework areas

These units should not be moved when raised to full height unless the design includes stabilisers and the manufacturer allows it.

Pallet jacks with scales

Weighing pallet jacks combine movement and weighing. They support applications such as

Checking incoming goods against shipping weight
Filling containers or ingredients to target weight at production lines
Recording outbound shipment weights for freight billing and compliance

Scale accuracy and legal for trade certification are important when weights feed directly into customer billing.

Stainless steel pallet jacks

Stainless pallet jacks serve hygiene and corrosion sensitive sites such as food plants pharmaceutical factories and some chemical facilities. Applications include

Moving ingredients in mixing and batching halls
Serving washdown packaging lines
Working inside clean room support areas

They tolerate regular washing and resist rust where standard painted steel trucks would fail early.

Electric pallet jacks and rider trucks

Electric pallet jacks take over where manual pulling would cause strain or limit throughput. Common applications are

High volume dock work in cross dock and parcel hubs
Long travel routes in large distribution centres
Multi shift operations where speed and reduced fatigue matter

Rider pallet trucks extend this by giving the operator a platform or seat. They are used in large warehouses and production plants with long clear aisles.

How pallet jacks support safety and ergonomics

Good application of pallet jacks reduces manual lifting and carrying. This protects backs shoulders and knees by keeping heavy loads on wheels instead of in workers hands.

Examples include

Sliding pallets directly from truck beds to pallet jacks instead of lifting boxes
Bringing pallets close to workstations so staff handle short reaches only
Using high lift pallet jacks where repetitive bending would otherwise be required
Switching from manual to electric pallet jacks for long routes or heavy daily volumes

Safe application means respecting rated capacities maintaining good floor conditions and training staff to steer park and store pallet jacks correctly.

Choosing pallet jacks for your applications

When you select pallet jacks for a site match the design to the main applications rather than buying a single generic model for every job.

Key points to consider are

Typical and maximum pallet weight
Pallet standards used in your supply chain
Floor and ground conditions indoor and outdoor
Travel distances and slope or ramp use

Required hygiene or corrosion resistance
Frequency of use and number of shifts
Space limits in aisles doors and vehicles

Often a mixed fleet works best. For example a warehouse may carry standard manual pallet jacks for light tasks electric pallet jacks for dock work and one or two stainless units for food or clean production zones.

Review applications each year as product mixes and layouts change. Adjusting pallet jack types to current work often delivers quick wins in productivity and safety.