Stacker Buying Guide: How to Choose

One of the most critical — and most overlooked — realities is that a stacker’s usable capacity often drops as you lift higher.

If you only check “rated capacity” at ground level, you can accidentally overbuy the wrong machine for racking work.

• Check your true working height (top rack placement + pallet height).
• Confirm residual capacity at height using the product’s load capacity chart (load curve).
• Be strict about load center: deeper/longer loads shift the center of gravity forward and reduce safe capacity.

This is the #1 “wrong purchase” cause: the stacker can lift the weight, but can’t actually pick the pallet.

Fork fit issues show up fast: scraping, jams, unstable lifting, or damaged pallets.

• Pallet entry width: forks must enter cleanly (no fighting the pallet every time).
• Fork pocket length: too short = unstable; too long = collision risk in tight staging lanes.
• Bottom design: open vs closed-bottom matters even if the forks fit.

A stacker’s turning behavior defines how efficiently your team can work. In tighter layouts, small clearance differences become daily friction.

• Measure your narrowest aisle (don’t use the “average aisle”).
• Measure turning points (end-of-aisle, dock corner, staging turns).
• Plan for real life: pallets left in aisles, traffic, and imperfect approaches.

Before you buy, measure the lowest clearance point your stacker must pass under (doors, beams, pipes). Then compare it to the machine’s mast-lowered height.

US buyers often underestimate how much surface and grade change daily usability and safety.

• Concrete quality: cracks, transitions, expansion joints, and ramps matter.
• Dock plates / thresholds: confirm clearance and stable movement across transitions.
• Outdoor exposure: wind, slope, and surface roughness increase control and stability requirements.

“Battery spec” isn’t just a number — it’s about how your team actually works and charges.

• Shift length: how long do you need consistent lift + travel performance?
• Charge behavior: do you have reliable time/space to charge, or do you need quick top-ups between tasks?
• Downtime cost: if waiting on charge stops the line, battery strategy becomes a productivity decision.

The right stacker type depends on how often you lift and how far you travel.

• Occasional use: short moves, light stacking, small backrooms.
• Daily replenishment: frequent lift cycles, repeated rack placement.
• Long travel routes: powered travel becomes the fatigue + productivity decider.

Beyond core specs, many US buyers look for “daily safety confidence” — especially in busy aisles and racking work.

• Braking confidence: predictable stopping matters most in tight zones and near docks.
• Visibility & control feel: smoother control reduces load swing and operator stress.
• Stability habits: keeping the load tight to the backrest and avoiding overreach becomes more important at height.

This is the part buyers often learn the hard way: the best-priced machine isn’t the best value if it’s down waiting for parts.

• Parts availability: reduces downtime risk and protects your schedule.
• Support responsiveness: matters when something needs diagnosis fast.
• Total ownership cost: service reality is part of ROI, not an afterthought.