What is a Electric-Stacker? Basic Types & Application

An electric stacker—also known as a pedestrian walk-behind stacker—is a type of walk-behind pallet truck equipped with a mast that allows it to lift pallets to various heights. Designed for versatility and ease of use, electric stackers come in several types, each suited to different operational needs. In this blog post, we’ll explore the different types of electric stackers and provide some basic application guidelines to help you choose the right one.

Electric stackers are available in both powered and manual models. They are ideal for lifting and moving pallets in environments where a full-size forklift isn’t necessary—such as store rooms, compact warehouses, and specialised storage areas. They can also serve as a cost-effective backup to more expensive forklift equipment.

These machines are best suited for handling small to medium loads and are typically used for tasks that require less than five hours of operation per day. Due to their compact wheels, electric stackers are primarily recommended for indoor use on flat, smooth surfaces like concrete floors. However, custom options—such as models with larger wheels—can be ordered for specific terrain or usage requirements.

Whether you’re looking to streamline operations in a small warehouse or improve safety and efficiency in tight spaces, electric stackers offer a practical and affordable solution for everyday material handling needs.

Types of Electric Stackers and Application Guidelines

Electric stackers come in a variety of configurations, each designed to meet specific material handling needs. The primary differences between them lie in how they distribute load weight—using either front legs, straddle legs, or a counter-balance system. Below is an overview of the most common types of electric stackers and their typical applications.

1. Electric Straddle Stacker

Electric straddle stackers are among the most widely used models, particularly in Australia. These stackers are equipped with straddle legs that extend around the sides of a pallet, allowing the operator to drive in closer without requiring as much clearance space.

Best suited for:

• Low- to mid-level selective racking

• Store rooms, compact warehouses, and customer-facing racking areas

• Floor stacking with closer pallet placement

Note: The racking system must allow space for the straddle legs to maneuver under or around the bottom beams.
Typical lifting height: 2,642 mm to 4,826 mm

2. Electric Reach Stacker

Similar in design to straddle stackers, electric reach stackers feature a pantographic scissor mast, which enables the forks to extend forward away from the body of the machine. This added reach makes them more versatile in loading operations.

Best suited for:

• Loading trailers, utility vehicles, and trucks

• Mid-level racking applications where extended reach is needed

Typical lifting height: 2,565 mm to 4,547 mm

3. Ride-On Electric Stacker

Ride-on electric stackers are built with a platform for the operator to stand or ride on, and they feature specialized driving controls. While they offer greater mobility and speed for larger spaces, a forklift license is required to operate them—unlike walk-behind models.

Note: For technical design details, see Standard Electric Stackers below.

4. Counter-Balance Electric Stacker

Counter-balance electric stackers use an internal counterweight system to balance the load, eliminating the need for external legs. This design makes them ideal for tight aisle environments and for handling standard pallets (with bottom boards), which are difficult to manage with other stacker types.

Best suited for:

• Narrow aisle operations

• Handling standard, fully enclosed pallets

• High-reach stacking

Consideration: Longer body length due to counterweight results in a larger turning radius.
Typical lifting height: 2,642 mm to 5,817 mm

5. Standard Electric Stacker

Standard electric stackers distribute weight through legs positioned underneath the forks, making them ideal for general transportation and stacking of bottomless pallets or containers.

Advantages:

• Compact turning radius

• Ability to transport and stack two pallets at once in some configurations

Limitations:

• Cannot lift standard bottomed pallets due to leg placement

Best suited for:

• Medium-level racking applications
  Typical lifting height: 1,845 mm to 4,255 mm

Manual-Powered Electric Stackers

These entry-level stackers are a hybrid between manual and electric models. While cost-effective, they have limited lifting height and speed, making them suitable only for very low-volume, general lifting tasks.

Not recommended for:

• Racking systems

• High-frequency use

Key Advantages of Using an Electric Stacker

Electric stackers offer a range of benefits that make them a practical and cost-effective solution for many material handling applications—especially in environments where space, cost, and emissions are key considerations. Here are some of the standout advantages:

• No Forklift Licence Required (for Walk-Behind Models)
  Operators do not need a forklift licence to use walk-behind electric stackers, making them easier to deploy in various workplace settings. However, users must be properly trained, understand all controls and safety procedures, and receive approval from their employer before operating the equipment. Note: Ride-on stackers still require a valid forklift licence.

• Lower Initial Investment
  Compared to larger material handling equipment such as forklifts, electric stackers come with a significantly lower upfront cost—making them an ideal entry-level or supplementary solution.

• Minimal Operating Costs
  Powered by rechargeable batteries, electric stackers have lower ongoing expenses than diesel, LPG, or CNG alternatives. There's no need for fuel purchases, and maintenance costs are typically lower due to fewer moving parts.

• Eco-Friendly and Quiet Operation
  Electric stackers produce no exhaust fumes or engine noise, making them perfect for indoor use. They contribute to a cleaner and quieter work environment while also reducing energy consumption and carbon emissions.

• Highly Maneuverable in Tight Spaces
  Their compact design allows electric stackers to operate efficiently in narrow aisles and tight warehouse spaces, helping to maximize floor space and improve workflow.

• Improved Operator Visibility
  The smaller size of electric stackers enhances forward visibility when handling loads, contributing to safer and more accurate operation.

Electric stackers are a smart solution for businesses that need efficient, flexible, and affordable pallet handling. With various models available to suit different load types, spaces, and lifting heights, choosing the right electric stacker can significantly improve your operational flow while keeping costs and emissions low.

If you're considering adding electric stackers to your warehouse or want expert advice on the best model for your needs, feel free to contact us. We're here to help you find the ideal equipment for your operations.