Thanks to the changing demands of sectors like retail, manufacturing, and e-commerce, warehouses are now expected to produce much higher throughput compared to just a generation ago. Today, even smaller warehouses are increasingly mechanising their operations just to match ever-increasing productivity needs. Devices that were once only seen in larger warehousing operations are now making their way into more businesses, including pallet jacks.

Pallet jacks are forklifts in their most basic form, allowing operators to move loads secured to standarised pallets within warehouses. Typically, warehouse operators have to choose between manual and electric pallet jacks.

Understanding the practical differences between these two categories can have a significant impact on productivity, safety, and overhead expenses.

What Are Manual Pallet Jacks?

Manual pallet jacks (also known as hand pallet trucks or hand trucks) are the simplest type of pallet-moving equipment. They only require human power to lift pallets and move loads across short distances. These are a staple in many smaller warehouses and retail businesses due to their affordability.

What Are Electric Pallet Jacks?

Electric pallet jacks (also called powered pallet trucks) are equipped with motorised mechanisms that assist users with lifting and moving pallets. Compared to manual models, these machines typically provide greater lifting capacity while also reducing the physical effort required from the operator. Even when rated for the same loads, an electric pallet jack will almost certainly boost the baseline productivity of the operator over a similar manual machine.

Pros and Cons of Manual Pallet Jacks

Recognisably, modern manual pallet trucks are at least over a century old, making them a tried and tested technology. However, their reliance on human power effectively bottlenecks their potential for efficiency.

Pros of Manual Pallet Jacks: 

1. Cost-Effective: Because they feature no motors or complex mechanisms, manual pallet jacks are typically much cheaper to acquire and maintain than their electric counterparts. However, these costs may be offset by lower productivity in busier warehousing operations.
2. Low Maintenance: Manual pallet jacks have few parts and generally only require basic maintenance. This makes them a good option when aftermarket service is unavailable or when a pallet jack is only needed infrequently.
3. Ease of Use: Minimal training is required to use these simple devices. Users can often learn how to operate one safely within minutes.

Cons of Manual Pallet Jacks 

1. Limited Capacity: Though there are some heavy-duty manual pallet jacks, there are practical limits to the weight they can safely handle. In larger warehouses, this can often mean more trips are needed to transfer the same load as a typical electric pallet jack.

2. Labour-Intensive: Using a manual pallet jack a main tool for warehousing requires a fair amount of physical fitness. Indeed, using one to cover longer distances in very large warehouses or on uneven surfaces between storage units is not always sustainable even for physically fit operators. Even under ideal conditions, relying on manual pallet jacks which can lead to worker fatigue and reduced productivity.
3. Speed and Efficiency: The limited weight capacity and human limitations of manual jacks make them significantly slower to operate compared to electric ones. In many cases, they’re unsuitable for larger warehouses or operations with a high expected throughput.

Pros and Cons of Electric Pallet Jacks

 Electric pallet jacks are an evolution of manual jacks, offering the typical advantages and downsides of motorised equipment.

Pros of Electric Pallet Jacks 

1. Increased Productivity: Electric pallet jacks can move heavier loads faster and with less effort than their manual counterparts. This means fewer trips needed to transfer any given load and more trips per day. These benefits make electric pallet jacks the clear choice for large, high-volume warehouses.
2. Reduced Physical Strain: The motorised assistance provided by electric pallet jacks reduces the physical strain on workers, leading to fewer injuries and less fatigue, with recommended usage practices.
3. Versatility: Electric jacks can move heavy loads over longer distances, with some even able to handle inclines and tight spaces. More complex, multi-building or multi-level warehouse environments are usually much better served by electric pallet jacks.

Cons of Electric Pallet Jacks

1. Higher Cost: The complexity of electric pallet jacks means they are necessarily more expensive to purchase and maintain. They also need regular battery replacement as well as charging infrastructure. However, these added costs may be worthwhile due to the significantly better productivity of these machines.
2. Maintenance Requirements: Motors, batteries, and electrical systems in modern electric pallet jacks are quite robust. However, they need a regular maintenance schedule to keep them in good working condition. Also, unlike manual pallet jacks, some electric pallet jacks may have parts that aren’t user-serviceable, potentially complicating the business’s operations.
3. Training and Safety: Electric pallet jacks are significantly more complex and powerful than a typical manual machine. This means that while they are easy to operate, operators need additional training to use them safely since there is a greater risk of accidents if the equipment is not used correctly. This also means that warehouses cannot risk letting uncertified personnel use these machines.

Keep Your Warehouse Operations Rolling Smoothly with the Right Pallet Jacks

If your warehouse has a complex environment, demands high throughput, or has limited manpower relative to its size, electric pallet jacks are probably the best all-around choice. These modern equipment handily lead their manual counterparts in efficiency, speed, and worker safety. However, if you have a smaller operation that only needs to move lightly loaded pallets a few times a day, a manual jack may be all that you need. With those pros and cons in mind, you can select a pallet jack type that boosts your warehouse’s productivity at a price that makes sense for your business’s bottom line.