Pallet trucks are indispensable tools in warehouses, factories, and retail operations. They facilitate efficient goods transportation and reduce the workload on workers.

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As warehouse and logistics operations undergo digital transformation, businesses face a critical decision: continue using traditional manual pallet trucks or invest in automated pallet trucks to enhance efficiency. Both have their advantages—but which one truly aligns with your needs? In this article, we will analyse the differences between the two, helping you determine which option is more suitable for your specific needs.

What Is a Manual Pallet Jack?

A manual pallet jack is a hand-operated tool designed to move pallets across short distances. It uses a hydraulic pump mechanism to lift loads just a few inches off the ground, allowing workers to manually push or pull them to the desired location. These are commonly used in small warehouses, retail backrooms, or areas with limited movement requirements.

What Is an Automated Pallet Truck?

An automated pallet truck is a driverless vehicle designed to autonomously transport palletized goods. Often powered by sensors, cameras, and advanced navigation software, these smart machines can perform repetitive material handling tasks without human intervention. They are a key part of many Industry 4.0 and smart factory initiatives.

They are ideal for large warehouses, production lines, and any scenario that requires frequent long-distance transport of goods.

Manual Pallet Jack: Pros and Cons

One of the biggest advantages of a manual pallet jack is its low upfront cost. It’s also easy to operate, requires minimal training, and doesn’t rely on electricity or batteries. For companies with limited warehouse space or low daily throughput, this simplicity can be a real benefit.

However, there are downsides. Manual pallet jacks depend entirely on human labor, which makes them inefficient for repetitive tasks. They also pose higher risks of workplace injury, especially when lifting heavy loads or maneuvering in tight areas. Over time, the cost of labor and the potential for injuries can outweigh the initial savings.

Automated Pallet Truck: Pros and Cons

Automated pallet trucks shine in environments where consistency, safety, and scalability matter. Once integrated into your warehouse system, they can run 24/7, reduce labor costs, and improve operational accuracy. Equipped with sensors and safety features, they also help minimize the risk of accidents.

The trade-off is the higher initial investment, as these systems require not only hardware but also setup, mapping, and software integration. Additionally, they may not be suitable for all warehouse layouts—particularly older facilities that weren’t designed with automation in mind.

When to upgrade?

Ask yourself the following questions:

• Have your operational needs changed?
• Is your business expanding?
• Are you facing labour shortages or rising labour costs?

When is it more appropriate to choose an automatic pallet truck?

Automated pallet trucks are ideal for:

• High-volume logistics centers or manufacturing plants
• Facilities looking to reduce long-term labor costs
• Operations requiring consistent, round-the-clock pallet movement
• Companies pursuing warehouse automation or digital transformation

Which One Is Better for Your Business?

If you’re managing a small warehouse with minimal daily pallet transfers, a manual pallet jack is likely sufficient. It's affordable, easy to use, and reliable for short-term needs.

But if your operation is growing, labor costs are rising, or you need to streamline material handling for better throughput and accuracy, an automated pallet truck could offer a better long-term return on investment.

Conclusion

Whether to choose a manual pallet truck or an automated pallet truck depends on your specific operational needs, budget, and growth plans. Manual tools are suitable for small businesses, but automation is the future direction for companies seeking scalability, efficiency, and reduced reliance on labour.

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If you operate on a smaller scale with fewer long-distance transport trips, a manual pallet truck may suffice. However, if you aim to scale up, improve efficiency, and reduce labour costs, we recommend investing in an automated pallet truck.

Advantages of Using Manual Pallet Trucks

Manual pallet trucks are designed to lift and transport pallets from one location to another safely. The need to safely load and unload pallets in workplaces has been recognised since the 19th century. MHA's range of Manual Pallet Trucks have become more prevalent and efficient for workplace and factory use, over the years. 

These days, pallet jacks are one of the most versatile material moving equipment in the industry. These can; 

• Easily move smaller and bigger goods from one location to another. 
• Stack goods on top of another.

As effective methods of handling various heavy goods, these are used in: 

• Manufacturing plants 
• Specialty and retail stores  
• Factory floors 
• Warehouse facilities

Injury probability is higher in manual pallet trucks than electric ones, since the former are manually operated. Therefore, you should adhere to loading specifications at all times. 

Types of Pallet Trucks

MHA's Pallet Trucks are cheap, and the steering depends on the operator control mechanism. They are suited to warehouses where pallets are stored at ground level. They are best for lifting comparatively small pallet stacks. 

Pallet trucks keep workers safe from injuries. Statistics show that most workplace injuries are due to handling heavy loads which can be avoided with: 

• A few pallet trucks; 
• The right sized trucks; 
• Trucks with the right capacity to safely move goods

Electric/Powered Pallet Jacks

In compariosn to manual Pallet Trucks/Jacks, Powered Pallet Jacks are sophisticated and require experienced operators. These trucks are used extensively in warehouses where pallets are raised and stacked in multiple layers. They are designed for lifting and moving bigger quantities of pallets. Electric pallet trucks require special attention when moving palettes: Up and down inclined surfaces, and through narrow spaces.

Some of MHA's range includes; The Edge Electric Pallet Truck and the electric pallet truck. In addition, pallet trucks with scales come with attached weighing scales that are located on the pallet truck and displays a pallet's weight. 

 Other pallet trucks are high lift pallet trucks, that are designed to: 

• Lift pallets to a safe working height;  
• Reduce injury complaints in the workplace; 
• Greatly assist packing and assembly workers.

Uses of Pallet Trucks

Bigger facilities have both the manual and electric models. In a warehouse, the right material handling equipment is extremely important. Available pallet trucks can easily move loads from 500kg to kg.

Manual pallet trucks are the most commonly used materials handling equipment where single pallets are moved over short distances in small workshops and manufacturing businesses. As mentioned, some pallet trucks come with integrated weighing scales and other accessories. These pallet trucks need to be extremely strong and functional as most carry heavy loads. Preferred in industries that deal with heavyweight equipment such as; retaiul stores, food service industries, warehouses and chemical factories. Usually made from stainless steel, some pallet trucks are galvanised to make them resistant to moisture. These are also used in: laboratories, clean rooms and for handling corrosive material.

Advantages of Using Pallet Trucks

In warehouses or factories, simple tasks such as lifting and organizing goods consume a lot of time. However, with high-quality pallet trucks in various sizes and load handling capacities, time is saved, and heavy goods are efficiently moved and organised.

In a warehouse with not enough space for bigger material handling equipment or forklifts, pallet trucks (also known as walkies or walk behind trucks) come in handy. Their hydraulic system has these features:  can be operated manually or by battery, and include built-in safety features. 

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