LindeMH Products
LindeMH Services
LindeMH Solutions
LindeMH About Us

Why Safe Operation of Pallet Jacks Matters

Warehouse safety is a top priority. Different machinery, such as order pickers and electric pallet jacks, require their own safety protocols. This guide will walk you through the key hazards, essential training considerations, and operational best practices to keep your workplace incident-free and efficient.

What is an Electric Pallet Jack?

How It Works

An electric pallet jack is driven by a battery-powered motor rather than manual force. While traditional jacks rely solely on operator strength to lift and move pallets, electric pallet jacks automate lifting, lowering, and travelling, making for smoother, safer handling of heavier loads.

Where It’s Used

Electric pallet jacks are the backbone in:

  • Warehouses
  • Retail backrooms
  • Grocery distribution centres
  • Loading docks and logistics hubs

They’re particularly valuable where repetitive movement or heavier pallets demand efficiency and reduced physical strain.

Why Safety Matters When Operating Electric Pallet Jacks

According to Safe Work Australia, materials handling equipment is among the top causes of warehouse injuries. A 2020 report indicated that around 30% of such incidents involved lifting or moving equipment. These accidents often stem from:

  • Load instability
  • Speed mismanagement
  • Limited operator visibility
  • Collisions with pedestrians

Taking safety seriously isn’t just smart — it’s legally essential and also helps avoid costly downtime.

Key Safety Hazards to Watch For

Overloading or Improper Load Handling

Exceeding weight limits can tip the jack or damage loads. Always balance and secure pallets, using standard stacking and strapping methods.

Operating on Inclines or Ramps

Gravity can work against you. On slopes, a poorly controlled descent can lead to rollbacks — never underestimate incline risks.

Blind Spots and Pedestrian Zones

With limited visibility in front or behind, operators must proceed cautiously and use clear communication to avoid accidents in pedestrian areas.

Step-by-Step Guide to Operating an Electric Pallet Jack Safely

  1. Inspect the equipment before use
  2. Wear appropriate PPE
  3. Position forks correctly under the pallet
  4. Check surroundings for pedestrians
  5. Use both hands on the controls
  6. Maintain a safe speed
  7. Lower the load before moving
  8. Park and switch off the jack safely

Pre-Operational Checks: What to Look For

  • Battery charge level
  • Tyre/wheel condition
  • Brake function
  • Horn and warning systems
  • Handle controls and buttons
  • Hydraulic lift system

These quick checks help catch faults before they become hazards.

Safe Driving Techniques for Electric Pallet Jacks

Maintain Safe Speeds

Especially critical in high-traffic warehouse zones where pedestrians and machinery mix.

Avoid Sharp Turns

Sharp manoeuvres with raised loads compromise the centre of gravity — slow and steady is the rule.

Look in the Direction of Travel

Never drive blind. When in reverse, move slowly, use mirrors if they are available, or walk behind when visibility is really poor.

Australian Training & Certification Requirements 

WorkSafe Western Australia outlines that while specific licensing for electric pallet jacks isn't generally mandated, operators must be trained in hazard awareness, safe handling, and workplace-specific procedures. Refresher training and adherence to internal site policies are essential to maintain competency and compliance.

Best Practices for Pallet Jack Safety in the Workplace

  • Have Marked Pathways and Signage: Designated routes keep traffic orderly and reduce cross-flow risks.
  • Team Awareness and Communication: Use horns, hand signals, or radios — especially in busy or noisy environments — to keep everyone in the loop.
  • Lockout/Tagout for Malfunctioning Equipment: If a jack is faulty, follow formal lockout/tagout protocols to ensure it’s safely taken out of service until repairs are complete.

Common Mistakes to Avoid

  • Riding the pallet jack
  • Moving too fast with heavy loads
  • Skipping inspections
  • Leaving forks raised when not in use

These shortcuts increase risk — resist the temptation and stick to best practice.

Electric Pallet Jack vs Manual Pallet Jack

Pros and Cons of Each

 

Type Pros Cons
Electric Pallet Jack Faster, less physically demanding, suitable for heavier loads Requires battery charging and more maintenance
Manual Pallet Jack Low maintenance, simple to use Physically demanding, slower, limited capacity

 

Training needs also differ: electric models require familiarity with controls and batteries, whereas manual jacks demand correct lifting and pushing technique.

Stay Safe, Stay Efficient

Safety isn’t optional; it’s central to workplace efficiency and morale. Consistent training, daily checks, and a culture that encourages accountability ensure that operations remain smooth and safe.

To explore the different types of electric pallet jacks that are available in the market today, explore our range.

 

VIEW ELECTRIC PALLET JACKS