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Choosing the Right Equipment for Your Warehouse

In any warehouse or logistics operation, choosing the right equipment can make or break your efficiency, safety, and bottom line. Whether you're running a high-volume e-commerce facility or managing pallets in a distribution centre, the machinery you rely on plays a vital role in daily operations.

Two of the most commonly used machines in warehouse environments are order pickers and forklifts. While they may look similar to the untrained eye, they’re built for very different tasks. Understanding the core differences is essential to ensuring you're using the right tool for the job.

This guide will break down everything you need to know about order pickers and forklifts: what they are, how they work, their pros and cons, and how to decide which is best for your operation.

What is an Order Picker?

How It Works

An order picker is designed for precision. Unlike forklifts, order pickers lift the operator along with the machine so they can access items on high shelves. Rather than moving entire pallets, order pickers are used for item-level picking, allowing for high accuracy when fulfilling individual orders.

Where It’s Commonly Used

Order pickers are typically found in:

  • Narrow aisle warehouses
  • E-commerce fulfilment centres
  • Inventory management and distribution facilities

Advantages of Using Order Pickers

  • Ideal for picking small items and individual orders
  • Space-efficient, they work well in tight spaces
  • Reduces picking errors through better visibility and access

Limitations to Consider

  • Not suitable for heavy loads or full pallets
  • Requires height-safety training for operators

What is a Forklift?

How a Forklift Works

A forklift is built for power and productivity. It lifts and moves entire pallets or heavy loads using forks, while the operator remains on the ground. Forklifts are more versatile and are used in a broader range of industries beyond warehousing.

Where Forklifts Are Most Effective

You’ll often see forklifts in:

  • Construction sites
  • Transport and logistics hubs
  • Loading docks and manufacturing plants

Advantages of Forklifts

  • Handles heavier loads with ease
  • Suitable for indoor and outdoor use
  • Faster movement for high-volume operations

Drawbacks of Forklifts

  • Requires more space to manoeuvre
  • Cannot pick individual items from racking

Order Pickers vs Forklifts – Key Differences Table

 

Feature Order Picker Forklift
Operator Elevation Yes – lifted with load No – remains on ground
Load Type Small individual items Full pallets or heavy items
Use Case Item picking, order fulfilment Pallet transport, loading/unloading
Aisle Width Compatibility Narrow aisles Needs wider space
Load Capacity Low to Medium Medium to High
Speed & Movement Slower, more precise Faster, less precision
Safety Concerns Height safety Load stability, clearance awareness
Training Requirements Height training required LF forklift licence (Australia)
Cost Lower (generally) Higher purchase and operating cost

 

Safety, Licensing & Training in Australia

Training Requirements for Forklifts

In Australia, anyone operating a forklift must hold a valid LF licence, which is issued by a Registered Training Organisation (RTO). Training covers operating procedures, safety checks, hazard management, and load handling.

Training for Order Pickers

Operators using order pickers — particularly those elevating above 2 metres, require working at heights training and, in some cases, an additional certification depending on the machine type. Safety is critical due to the elevation and potential fall risks.

Common Mistakes When Choosing Between a Forklift and an Order Picker

Avoid these costly errors:

  • Choosing based on price, not application
  • Ignoring aisle width or ceiling height
  • Overlooking licence or training availability

Industry Use Cases in Australia

Example – E-Commerce Warehouse

E-commerce facilities often benefit from order pickers due to their ability to navigate narrow aisles and support fast, accurate picking of individual items.

Example – Logistics and Transport Business

In contrast, forklifts are better suited for logistics providers where full pallet movement, speed, and load handling are key to daily operations.

Pros and Cons Recap

Pros of Order Pickers

  • Accurate item picking
  • Great in tight warehouse spaces

Cons of Order Pickers

  • Limited to smaller loads
  • Requires height-related training

Pros of Forklifts

  • Lifts heavy loads easily
  • Suitable for versatile environments

Cons of Forklifts

  • Requires more floor space
  • Needs an LF licence to operate

How to Decide Which Machine You Need

Here’s a quick checklist to guide your decision:

  • What kind of items are you moving: individual boxes or full pallets?
  • Is space tight in your facility?
  • Do you already have licensed operators?
  • Do you prioritise speed or precision?
  • What’s your budget for purchase and maintenance?

Not sure what fits best? Explore our range of order pickers and forklifts or get in touch with our team to discuss your specific needs.

Making the Right Choice

Choosing between an order picker and a forklift is not just about load size or speed; it’s about the right fit for your workflow, space, and safety standards.

If your operation involves high-frequency picking in tight areas, an order picker is your best mate. But if you’re dealing with bulk pallet transport and varied tasks, a forklift might be the powerhouse you need.

Need help choosing the right equipment? Contact us to understand what material handling solutions are best suited to your application today.

 

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