Reach Trucks vs. Order Pickers: Key Differences, Uses, and Which One Your Warehouse Needs

In the fast-paced world of warehousing and logistics, choosing the right equipment can make a significant difference in efficiency and productivity. Two of the most essential machines used in warehouse operations are reach trucks and order pickers. While both are designed for material handling, they serve distinct purposes and are optimized for different tasks.

This article will explore the key differences between reach trucks and order pickers, their primary uses, advantages, and how to determine which one best suits your warehouse needs. If you're looking for in-depth specifications, reviews, and comparisons, AllMachines is the best source for forklift and material handling equipment information.

What Is a Reach Truck?

A reach truck is a type of forklift specifically designed for use in warehouses with high-rack storage. These machines are optimized for lifting and retrieving pallets from shelves that are stacked several levels high while operating efficiently in narrow aisles.

Key Features of a Reach Truck:

Extended Mast and Reach Mechanism: Unlike standard forklifts, reach trucks can extend their forks forward to "reach" into racking, allowing them to retrieve or store pallets deep within shelving.
High Lifting Capabilities: Typically, reach trucks can lift loads up to 30-40 feet, making them ideal for high-bay warehouses.
Compact Design: Built for tight spaces and narrow aisles, they allow warehouses to maximize storage density.
Sideways Stance for Operators: Many reach trucks have a side-facing operator compartment, improving visibility and reducing strain during long shifts.

Common Applications of Reach Trucks:

High-density storage warehouses where maximizing vertical space is crucial.
Cold storage facilities that require efficient space utilization.
Retail distribution centers that store large quantities of palletized goods.

What Is an Order Picker?

An order picker is a type of lift truck designed for manual order fulfillment rather than handling entire pallets. These machines allow operators to elevate themselves alongside the shelving units, making it easy to pick individual items from multiple levels.

Key Features of an Order Picker:

Operator Platform Elevation: The most notable feature is that the operator's compartment rises with the forks, allowing for direct access to inventory.
Light to Medium Load Capacity: Order pickers typically handle lighter loads, making them ideal for e-commerce warehouses, retail inventory, and parts distribution centers.
Compact and Maneuverable: Order pickers are built for narrow aisles, allowing operators to efficiently move within tight warehouse layouts.
Electric-Powered Operation: Most order pickers are battery-powered, providing quiet operation and reducing emissions in indoor environments.

Common Applications of Order Pickers:

E-commerce fulfillment centers where workers need to pick and pack individual items.
Parts and component warehouses that handle small to medium-sized inventory.
Retail stockrooms where quick and frequent access to shelves is necessary.

Key Differences Between Reach Trucks and Order Pickers

Feature	Reach Truck	Order Picker
Primary Function	Lifting and storing full pallets	Picking individual items from shelves
Operator Position	Stays on the ground	Moves up with the lifting platform
Lifting Height	30-40 feet	Typically 10-30 feet
Load Capacity	Higher (1,500-5,500 lbs)	Lower (typically 1,000-3,000 lbs)
Best for	Palletized goods, high-bay storage	Order fulfillment, retail stockrooms
Aisle Space Needed	Narrow but wider than an order picker	Very narrow, ideal for compact warehouses
Power Source	Electric	Electric

Best Use Cases: When to Choose a Reach Truck vs. an Order Picker

Choose a Reach Truck If:

✅ Your warehouse stores large volumes of palletized inventory.

✅ You need to maximize vertical storage space.

✅ Your aisles are narrow but require high-capacity lifting.

✅ You primarily move full pallets rather than individual items.

Choose an Order Picker If:

✅ Your operation focuses on individual item selection rather than full pallets.

✅ You run an e-commerce, retail, or parts distribution center.

✅ You need to optimize for fast and efficient picking.

✅ Your warehouse has narrow aisles with shelving instead of pallet jacks.

Pros and Cons of Reach Trucks vs. Order Pickers

Reach Truck: Pros & Cons

✔ Pros:

✔ High lifting capacity for palletized storage.

✔ Compact design for efficient use of space.

✔ Ideal for high-volume warehouse operations.

❌ Cons:

❌ More expensive to purchase than standard forklifts.

❌ Not suitable for individual item picking.

❌ Requires more operator training due to reach mechanism.

Order Picker: Pros & Cons

✔ Pros:

✔ Perfect for e-commerce and retail fulfillment.

✔ Reduces the need for ladders, improving worker safety.

✔ Highly maneuverable in narrow aisle spaces.

❌ Cons:

❌ Lower lifting capacity than reach trucks.

❌ Not designed for moving full pallets.

❌ Requires operator elevation, which may pose safety risks.

Cost & Maintenance Comparison

Initial Investment:

Reach trucks tend to have a higher upfront cost, typically ranging from $25,000 to $50,000, depending on specifications.
Order pickers are generally more affordable, with prices ranging from $15,000 to $35,000.

Maintenance Costs:

Reach trucks require more frequent servicing, especially for hydraulic components and reach mechanisms.
Order pickers have lower maintenance costs, but their batteries need regular upkeep for optimal performance.

Long-Term Investment:

Reach trucks retain their value better for pallet-based warehouses, making them a strong long-term investment.
Order pickers are cost-effective for businesses with high order fulfillment needs, providing quicker ROI in e-commerce and retail settings.

Safety Considerations

Safety is a crucial factor when choosing between a reach truck and an order picker.

Reach Trucks: Require proper training to operate safely at high lift heights, ensuring stability while handling heavy pallets.
Order Pickers: Since the operator moves up and down, additional fall protection and training are required to prevent accidents.

Both machines require regular maintenance, operator training, and adherence to OSHA guidelines to ensure safe operation in a warehouse environment.

Final Verdict: Which One Should You Choose?

The choice between a reach truck and an order picker depends entirely on your warehouse operations:

If your business involves high-rack storage and moving full pallets, a reach truck is the best choice.
If your priority is fast and efficient order fulfillment, an order picker will significantly improve productivity.

For businesses looking to optimize their warehouse operations, investing in the right equipment is crucial for efficiency and cost savings.

For detailed comparisons, expert reviews, and specifications on reach trucks and order pickers, AllMachines is the ultimate resource for warehouse managers and logistics professionals.

Conclusion

Choosing between a reach truck and an order picker depends on your specific warehouse needs. Reach trucks are ideal for high-capacity, palletized storage, while order pickers excel in fast and precise order fulfillment. By understanding their differences, strengths, and limitations, businesses can make informed decisions to boost warehouse efficiency.

For the best insights, reviews, and specifications on warehouse equipment, visit AllMachines, the top source for material handling solutions.