Selection
Manual vs electric vs weighing pallet trucks compared on cost, duty cycle, floor condition and distance travelled — with guidance on when a powered truck pays for itself.
Last updated: 11 October 2026
A pallet truck is the cheapest piece of equipment in the warehouse and the one used most. Choosing the wrong type is not expensive in itself — it is expensive in the labour it wastes every single day.
The four questions that decide it
- **How far does a pallet travel per trip?** Under 15 m, manual is fine. Over 30 m, an operator loses measurable time every trip and an electric truck pays back within months.
- **How many pallets a day?** Under about 40, manual. Over 100, powered.
- **What is the floor like?** Smooth concrete suits nylon or polyurethane wheels. Rough or outdoor ground needs rubber and probably suspension.
- **How steep is the ramp or dock plate?** Manual trucks on a slope are a safety problem, not just an effort problem.
Manual pallet trucks
The default choice for short-distance, low-frequency movement. Look for a forged lifting arm, welded forks and an overload-protected pump. Wheel choice matters more than most buyers expect: nylon is durable and rolls easily on smooth concrete, polyurethane is quieter and kinder to floors, rubber grips on rough ground.
Electric pallet trucks
Powered travel and lift. The payback is purely a function of distance and volume. Two specifications to get right:
- **Battery.** Lead-acid if you run one shift and have a charging corner. Lithium if you run multiple shifts or have no space for a battery room — it opportunity-charges in breaks.
- **Travel speed.** A truck limited to walking pace will not save the time you bought it for. Check laden and unladen speeds.
Weighing pallet trucks
A pallet truck with a built-in scale. Worth it if you charge out by weight, check incoming goods against a delivery note, or fill containers by weight. Check the accuracy class and the IP rating of the indicator — a scale that fails in a wash-down area is worse than no scale.
What actually breaks
In our experience the failure points, in order, are: pump seals, load wheels, and the handle return spring. Buying a truck with a serviceable pump and standard-size wheels will save more over five years than any other decision on this list.
Need help choosing the right truck?
Send us your load weight, lifting height and aisle width — we will recommend the right model.
Frequently asked questions
How do I choose a pallet truck?
Daily move count and travel distance decide it: under 20 moves and 30 m, manual is enough. Above that, specify electric.
What is a scale pallet truck for?
Weighing while moving, useful where goods are received or issued by weight — it removes a separate weighbridge step.
Can a manual pallet truck be used on a ramp?
Not advisable. Manual trucks are hard to control on gradients and can run away. Specify a braked electric model instead.
