Order picking forklifts increase warehouse productivity by 35% while reducing order fulfillment errors by 28% (MHEDA, 2023). To operate order picking forklifts efficiently, operators must be trained and certified. In Australia, this involves obtaining an LF and LO license. These specialized “picker forklift” machines have become essential equipment in modern warehouses handling over 500 SKUs.
What Is an Order Picking Forklift?
An order picking forklift is a specialized material handling vehicle designed for efficient case picking and item selection: Unlike traditional forklifts, these “order picker lift” machines prioritize operator elevation over pure lifting capacity.
- Also called order picker forklifts or stock picker forklifts
- Platform elevates operator to picking levels (up to 40 feet)
- Reduces walking time by 80% compared to traditional picking (Modern Materials Handling, 2022)
- Features integrated controls for precise positioning at height
- Designed specifically for “order picking” operations in high-density storage
Key Components of an Order Picker Forklift Truck
How Does an Order Picker Forklift Work?
These picker lift trucks combine vertical lifting with operator platforms for direct access to inventory: The “what is an order picker” question is best answered by understanding its unique operational workflow.
| Component | Function | Safety Features |
|---|---|---|
| Elevating Platform | Raises operator to exact picking height | Fall arrest anchors |
| Fork Positioners | Adjustable forks for various pallet sizes | Automatic leveling |
| Safety Rails | Protect operator at height | Kick plates |
Order picking forklifts are engineered for navigation through narrow aisles and elevated storage locations, frequently requiring a certified lo operator to ensure safe and compliant use in warehouse environments.
Operational Sequence: 1) Operator drives to picking location → 2) Elevates to exact SKU height → 3) Selects items while secured to platform → 4) Lowers completed order to ground level → 5) Transports to packing station.
Types of Order Picker Forklift Trucks
Three main configurations dominate the market (Industrial Truck Association, 2023):
- Low-level order pickers (LOPs): For picking under 12 feet (ideal for small warehouses with lower racking)
- High-level order pickers: Reach up to 40 feet (require LO licence in Australia)
- Turret trucks: Combine order picking with very narrow aisle capability (most space-efficient option)
- Bidirectional models: Allow picking from both sides of the aisle (increase pick rates by 15-20%)
Benefits of Using Order Picking Forklifts
Warehouses report 45% faster order fulfillment with picker forklifts (Logistics Management, 2023): These “order picking forklift truck” advantages explain their rapid adoption across Australian warehouses.
- Reduce labor costs by 30% through improved efficiency
- Decrease product damage by 22% with precise picking
- Improve ergonomics by eliminating ladder use
- Increase storage density through vertical space utilization, order picker training guide to help you get fully licensed and compliant.
- Enhance inventory accuracy with integrated scanning stations
- Reduce worker compensation claims by 40% (SafeWork Australia, 2023)
Order Picker Forklift vs. Traditional Picking Methods
Picker lift trucks outperform manual methods in speed and accuracy: The “order picking” efficiency gains are most apparent in high-volume operations.
| Metric | Order Picking Forklift | Manual Picking | Advantage |
|---|---|---|---|
| Picks per hour | 120-150 | 60-80 | 85% faster |
| Error rate | 0.5% | 2.5% | 80% reduction |
| Operator fatigue | Low | High | Ergonomic benefit |
Australian Compliance Considerations
All order picking forklifts in Australia must comply with:
- AS 2359 – Powered industrial trucks standards
- Work Health and Safety Regulations 2011
- State-specific requirements for high-reach equipment
What’s the difference between an order picker and a stock picker forklift?
These terms are often interchangeable, though some manufacturers use “stock picker” for heavier-duty models handling bulkier items. Key distinction: order pickers prioritize operator elevation while stock pickers focus on load capacity.
How much weight can order picking forklifts handle?
Most models handle 2,000-4,500 lbs, with some heavy-duty versions lifting up to 6,000 lbs (OSHA standards). Australian models typically range from 1,000kg to 2,500kg capacity.
Do operators need special certification for order picker forklifts?
Yes, OSHA requires specific training for all powered industrial trucks, including order picking forklift trucks. In Australia, LO licence is mandatory for high-level order pickers under WorkSafe regulations.
Can order picker forklifts be used in cold storage?
Many models are available with cold storage packages for temperatures as low as -30°F. Australian cold chain operations often use specialized models with anti-condensation electronics.
What aisle width is needed for order picking forklifts?
Standard models require 8-10 feet aisles, while narrow-aisle versions work in 6-7 foot spaces. Turret trucks can operate in aisles as narrow as 5.5 feet.
References
- MHEDA Industry Reports
- OSHA Powered Industrial Truck Standards
- Modern Materials Handling: Order Picking Trends
- SafeWork Australia Equipment Guidelines
- Australian Standard AS 2359 – Powered Industrial Trucks
