Choosing the right pallet jack for your operation

Moving pallets looks simple on the surface. In reality the type of pallet you use, the space you work in and the way goods flow through your site all affect which pallet jack (or truck depending on what term you like to use!) will actually make your operation faster and safer.

Picking the wrong one can mean awkward lifting angles, wasted time lining up forks and unnecessary strain on your team.

This guide walks through the key factors to consider so you can match the right pallet jack to your pallets, your layout and your workflow.

Start with the pallet you are handling

Before looking at product codes or deciding between manual and electric, focus on the pallet itself.

Different pallet formats have different fork entry heights, widths and lifting points. These details determine whether a pallet truck will slide in cleanly or get stuck before the forks even reach the load.

Common pallet types in New Zealand warehouses and distribution environments include:

• Blue CHEP pallets
• Standard industrial pallets
• Euro pallets
• Bins and stillages

Each of these has different dimensions and lifting requirements. Understanding what you are moving every day is the first step toward improving efficiency and avoiding handling issues.

Why Blue CHEP pallets need special attention

Blue CHEP pallets are widely used across retail, FMCG and logistics. They are durable, reusable and designed for high volume environments. They also offer four way entry, which means a forklift or pallet jack can lift from any side.

However there is a catch that often gets overlooked.

Two sides of a CHEP pallet have fork entry openings of around 98 mm high
The other two sides are smaller, typically 65 to 70 mm high

Most standard pallet jacks have a minimum lowered fork height of about 75 to 80 mm. That means they physically cannot enter the smaller openings.

In practice this limits you to lifting from only two sides of the pallet. If those sides are blocked by racking, walls or other pallets, you end up repositioning loads or manually shifting pallets to get access. That slows your operation and increases handling risk.

The practical impact on workflow

When a pallet can only be lifted from certain sides, small layout constraints become bigger productivity issues.

1. Operators spend extra time lining up forks
2. Pallets need to be turned before lifting
3. Congested areas become harder to manage
4. Manual handling increases

Over the course of a shift this adds up to lost time and unnecessary strain. In high throughput environments the right pallet truck can remove these friction points completely.

The solution for CHEP pallets – low profile four way pallet jacks

A four way manual pallet truck, often called a low profile pallet jack, is designed specifically to handle pallets with reduced fork entry height.

The key difference is the minimum lowered fork height.

• Low profile models sit at around 60 to 65 mm
• This allows them to enter even the smaller CHEP pallet openings
• You regain true four way access

This means operators can lift a pallet from any side without repositioning it. In tight spaces that flexibility makes a noticeable difference to productivity and safety.

Fork dimensions that suit CHEP pallets

To work effectively with CHEP pallets the fork size also needs to match the pallet structure.

A typical configuration is:

• Fork width between 520 and 550 mm
• Fork length around 1220 mm

The longer fork length ensures the forks reach the bearers at the far end of the pallet. That provides better load stability and reduces the risk of tipping during transport.

Manual and electric options for four way handling

Low profile pallet trucks are available in both manual and electric models, depending on the intensity of your operation and the distances involved.

Manual four way pallet jacks

JF2048
JF2036
PL2048G

Electric four way pallet jacks

EPT2048 2T
EPT2048 1.5T

Manual models suit lower throughput environments or shorter travel distances. Electric models reduce operator fatigue and are better suited to frequent movement across larger floor areas.

When you are using Euro or standard industrial pallets

If your operation primarily uses Euro pallets, standard industrial pallets or bins, the requirements are different.

These pallets typically have larger fork entry heights, so a standard pallet truck with a minimum lowered height of 75 to 80 mm works without issue.

In these cases the focus shifts from fork height to fork length and load stability.

The forks should extend fully through the pallet or bin so the load is supported across its full length. Short forks can leave weight unsupported, increasing the risk of pallet damage or load shift during movement.

Common pallet truck sizes for these applications

A widely used configuration for standard pallets is:

• PL2742 manual pallet truck
• EPT2742 electric pallet truck

These provide the correct fork dimensions and lifting capacity for most general warehousing and manufacturing environments.

Matching the pallet truck to your environment

Beyond pallet type there are a few practical questions that help narrow down the right model.

• How much space do you have to manoeuvre?
• How far are pallets typically moved?
• How frequently are pallets handled each shift?
• What is the average load weight?

Tight aisles and congested areas benefit from four way access and shorter turning radii. Longer travel distances and high volume movement often justify electric models to reduce fatigue and maintain consistent productivity.

Safety and load stability considerations

Using the correct fork length is not just about efficiency. It also affects safety.

Forks that do not reach the far bearer can cause pallets to flex or tilt under load. Over time this increases wear on pallets and creates a higher risk of dropped loads.

Ensuring the fork length matches the pallet length provides:

• Better weight distribution
• Improved control during movement
• Reduced pallet damage
• Safer handling for operators

A quick decision framework

If you are unsure which pallet truck suits your operation, start with these checkpoints.

1. Identify your primary pallet type
2. Check the fork entry height of that pallet
3. Match the pallet jack minimum fork height to suit
4. Confirm the fork length supports the full pallet
5. Choose manual or electric based on travel distance and frequency

This approach removes guesswork and ensures the equipment fits your real world workflow.

Improving efficiency through the right equipment choice

The right pallet jack does more than move goods from A to B. It reduces handling time, improves operator comfort and keeps your warehouse flowing smoothly.

For CHEP pallet users, a low profile four way pallet truck removes a common bottleneck and restores full access in tight spaces.

For standard pallets and bins a correctly sized pallet jack with full length fork support ensures stable and efficient movement.

Small equipment decisions like this have a measurable impact on daily productivity and long term safety.

Where to go next

If your team is working around pallet access issues, lifting from only certain sides or manually repositioning loads, it is worth reviewing whether your current pallet trucks match your pallet type.

A short assessment of pallet dimensions, fork heights and travel distances can quickly highlight opportunities to improve flow and reduce handling effort.

Choosing the right pallet jack is not about buying more equipment. It is about selecting the configuration that fits the pallets you already use and the way your operation actually runs.