Understanding the Different Types of Forklift Trucks Used with Warehouse Pallet Racking in the UK

Efficient warehouse operations depend on selecting the right forklift truck for the storage system being used. Match the right truck to the right pallet racking system to improve productivity, maximise capacity, and enhance safety.

In the UK, warehouses vary significantly in size, layout, aisle width, racking height, and stock handling requirements. As a result, there is no single forklift that suits every application.

Whether operating a small stockroom, a large distribution centre, or a high-density pallet racking facility, understanding the different types of forklift trucks available can help improve productivity, maximise storage capacity, and enhance workplace safety.

Why Forklift Selection Matters

The relationship between pallet racking and forklift trucks is critical. The wrong truck can limit storage density, reduce picking efficiency, increase product damage, and create safety risks. When selecting a forklift, warehouse managers should consider:

The Most Common Forklift Truck Types in UK Warehouses

Counterbalance Forklift Trucks

The most widely recognised forklift in the UK. Forks at the front, counterweight at the rear — no outriggers required.

Advantages

  • Versatile and easy to operate
  • Suitable for loading and unloading vehicles
  • Available in electric, diesel, and LPG
  • Indoor and outdoor use

Limitations

  • Requires wider aisles (3–4m)
  • Less efficient in high-density racking

Typical Applications

General warehousing · Manufacturing · Builders' merchants · Loading bays · Yard operations

Reach Trucks

Designed specifically for pallet racking. The mast extends forward to place pallets before retracting back, allowing operation in much narrower aisles.

  • Excellent lift heights (often 13m+)
  • Narrow aisle operation
  • Increased storage density
  • Ideal for indoor warehouse use
  • Not suited to rough outdoor surfaces
  • Less effective for loading lorries outdoors

Distribution centres · Retail warehouses · Third-party logistics · High-bay pallet racking

Very Narrow Aisle (VNA) Forklift Trucks

Operates in aisles as narrow as 1.6–2m. Stays aligned with the racking while specialised fork mechanisms rotate or move sideways to access pallets.

  • Maximises warehouse storage capacity
  • Reduces wasted aisle space
  • Suitable for very high racking
  • Excellent cube utilisation
  • Requires carefully planned layouts
  • Often dependent on guidance systems
  • Higher initial investment

Large distribution centres · E-commerce fulfilment · High-density storage operations

Articulated Forklift Trucks

Combines the flexibility of a counterbalance truck with the narrow aisle capability of a reach truck. The front section pivots to access racking.

  • Indoor and outdoor capability
  • Reduced aisle widths
  • Versatile operation
  • Can unload vehicles and service racking
  • Operator training requirements
  • Slightly slower than specialist VNA systems

Multi-purpose warehouses · Growing businesses · Mixed indoor/outdoor operations

Pallet Trucks

Designed for moving pallets at ground level. Available as manual (pump trucks) or electric. Not for placing pallets into racking.

  • Cost-effective
  • Easy to operate
  • Ideal for horizontal pallet movement
  • Limited lifting capability
  • Not suitable for standard pallet racking

Goods-in areas · Loading bays · Retail stockrooms · Short-distance pallet transport

Powered Stacker Trucks

Bridges the gap between pallet trucks and full forklifts. Lifts pallets to moderate heights where a full forklift is not required.

  • Compact design
  • Lower cost than forklifts
  • Suitable for small warehouses
  • Limited lift height
  • Lower capacity than reach trucks

Small warehouses · Stockrooms · Light industrial facilities

Order Pickers

Designed for piece-picking rather than full pallet handling. The operator platform rises with the forks for direct access at height.

  • Efficient order fulfilment
  • Increased picking accuracy
  • Improved productivity
  • Not intended for pallet storage operations
  • Specialist application

E-commerce warehouses · Retail distribution centres · Spare parts facilities

Turret Trucks

Highly specialised. Designed for high-level pallet handling in very narrow aisles, rotating forks independently of the chassis.

  • Exceptional storage density
  • High lift heights
  • Fast pallet access
  • Significant capital investment
  • Requires dedicated warehouse design

Automated and semi-automated warehouses · High-volume distribution · High-bay storage

Electric vs Diesel vs LPG Forklifts

Electric Forklifts

Dominate modern UK warehouses. Zero tailpipe emissions, lower maintenance, quieter operation, and ideal for food and pharmaceutical environments.

Diesel Forklifts

Strong outdoor performance, high power output and long operating periods. Generally unsuitable for enclosed warehouse environments.

LPG Forklifts

A balance between electric and diesel — fast refuelling, suitable for indoor and outdoor use, with good performance levels.

Matching Forklifts to Pallet Racking Systems

Safety Considerations

Regardless of forklift type, safe operation remains essential. UK warehouse operators should ensure:

Proper forklift selection and operator training can significantly reduce accidents, product damage, and costly downtime.

Conclusion

The forklift truck market offers a wide range of solutions designed for different warehouse environments and pallet racking systems. Counterbalance forklifts remain popular for general-purpose use, while reach trucks, articulated forklifts, VNA trucks, and turret trucks provide increasingly specialised solutions for maximising storage density and operational efficiency.

Choosing the correct forklift should always be based on aisle width, lift height, pallet weight, warehouse layout, and long-term operational goals. By matching the right truck to the right pallet racking system, UK warehouses can improve productivity, increase storage capacity, and maintain a safer working environment.

Frequently Asked Questions

Which forklift is best for UK warehouse pallet racking?

What aisle width do reach trucks need?

Are electric forklifts suitable for all UK warehouses?

Do I need to change my racking if I change forklifts?

Can Rackstor advise on forklift compatibility?

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