Forklifts, Reach Trucks & Pallet Trucks Explained

Résumé rapide :
Cold storage warehouse performance depends less on individual machines and more on the balance between forklifts, reach trucks, and pallet trucks. This article explains how each equipment type contributes to flow, density, and stability—and how the right equipment mix prevents congestion, underutilization, and unnecessary cost in frozen and chilled warehouses.

1. Why “More Equipment” Rarely Fixes Cold Storage Problems

When cold storage operations struggle, the most common reaction is:

“Add more forklifts.”

In reality, most cold storage inefficiencies are caused by:

  • Wrong equipment doing the right job

  • Right equipment doing the wrong job

  • One machine type forced to cover all tasks

Cold storage is unforgiving:
misused equipment creates bottlenecks faster than insufficient equipment.

This is why equipment mix matters more than fleet size.

2. The Three Core Equipment Roles in Cold Storage

At a system level, cold storage handling relies on three distinct roles:

Problems arise when these roles overlap without control.

📊 Forklifts vs Reach Trucks vs Pallet Trucks — Functional Overview

Type d'équipement Primary Role Strength Common Misuse
Electric Forklifts (e.g. E16) General flow & flexibility Stable, versatile, forgiving Used for all tasks by default
Chariots à mât rétractable Vertical access High-bay efficiency Used for horizontal transport
Electric Pallet Trucks (e.g. T20B) High-frequency short moves Speed, low congestion Ignored or under-deployed

Each machine is efficient only within its natural role.

chariot à contrepoids

chariot à contrepoids

3. Forklifts: The Rhythm Keepers of Cold Storage

Electric forklifts form the backbone of most cold storage operations.

Where Forklifts Perform Best

  • Dock-to-staging movements

  • Selective racking (low to mid levels)

  • Cross-docking

  • Mixed and exception handling

Why Forklifts Are Often Overused

Because they are flexible, forklifts are often asked to do everything—
which leads to:

  • Congestion

  • Energy waste

  • Operator fatigue

Forklifts should connect processes, not dominate all of them.

4. Reach Trucks: Density Specialists, Not Flow Machines

Reach trucks exist for one primary reason:

To make high-density racking usable.

Where Reach Trucks Are Essential

  • High-bay selective racking

  • Rayonnage à double profondeur

  • Narrow aisle cold storage

Where Reach Trucks Create Problems

  • Dock areas

  • Long horizontal travel

  • Repetitive short-distance moves

Using reach trucks outside aisles often reduces throughput instead of increasing capacity.

Chariot élévateur5. Pallet Trucks: The Hidden Throughput Multiplier

Electric pallet trucks are frequently underestimated in cold storage design.

Where Pallet Trucks Deliver Maximum Value

  • Truck loading and unloading

  • Dock buffer movement

  • Short-distance repetitive transport

Replacing forklifts with pallet trucks in these zones:

  • Reduces congestion

  • Improves door throughput

  • Frees forklifts for value-added tasks

In many cold storage docks, pallet trucks handle more pallet moves than forklifts, quietly stabilizing the system.

6. The Most Common Equipment Mix Mistakes

Across cold storage projects, the same mistakes repeat:

  • Too many reach trucks, too few forklifts

  • Forklifts used where pallet trucks should dominate

  • Pallet trucks treated as secondary equipment

  • Equipment mix decided by budget, not flow

These mistakes rarely appear on drawings—but show up daily in operations.

7. A Practical Equipment Mix Logic (Used in Real Projects)

While every warehouse is different, a practical reference mix often looks like:

  • Forklifts: 50–60% of handling equipment

  • Reach trucks: 25–35%, focused on racking aisles

  • Pallet trucks: 15–25%, concentrated at docks

The exact ratio varies, but the principle is constant:

Flow first, density second.

8. Cold Storage Reality: Peaks Expose Bad Equipment Mix

During peak seasons:

  • Forklifts queue

  • Reach trucks are overextended

  • Pallet trucks are suddenly “missing”

If peak operations feel chaotic, the issue is rarely labor—it is usually equipment imbalance.

9. How Equipment Mix Affects ROI

Correct equipment mix:

  • Reduces total fleet size

  • Improves effective utilization

  • Lowers energy and maintenance cost

  • Delays automation CAPEX

Incorrect mix:

  • Inflates hidden operating cost

  • Forces premature automation

  • Masks design flaws with labor

Equipment mix is therefore a financial decision, not just a technical one.

10. Sujets populaires de Google (réponses contextuelles)

Why do cold storage warehouses need different equipment types?
Because different tasks require different movement characteristics.

Can forklifts replace pallet trucks?
Not efficiently in high-frequency dock operations.

Do reach trucks improve throughput?
They improve density, not flow.

What causes congestion in cold storage?
Misuse of forklifts and reach trucks for the wrong tasks.

Is there a standard equipment mix?
There is no fixed ratio, but clear role separation always improves performance.