Picking Pallets Off the Ground with a Pallet Stacker: Best Practices and Tips

[MikePhua]

When working in warehouses, factories, or construction sites, efficient handling of pallets is essential for maximizing productivity. One of the most common tasks is picking up pallets from the ground and moving them to different locations. While forklifts are often the go-to equipment for lifting and transporting pallets, pallet stackers—especially manual and electric models—offer a more maneuverable solution for smaller or tighter spaces.
The use of pallet stackers is widespread, particularly in operations where the volume of material handling isn't as large as what a forklift can handle. Despite being lightweight and compact, pallet stackers can be highly effective when operated correctly. This article will explore how to safely and effectively pick pallets off the ground using a pallet stacker, the challenges involved, and some helpful tips to enhance efficiency and safety.
Understanding the Pallet Stacker
A pallet stacker is a type of material handling equipment designed primarily for lifting and moving pallets, often in environments where forklifts might be too large or impractical. Pallet stackers come in various designs, with manual, electric, and semi-electric options available. They consist of two main components: a set of forks and a lifting mechanism that raises and lowers the pallet.
The manual pallet stacker is typically operated by hand, where the user pumps a lever to raise the forks and moves the stacker by pushing or pulling it. Electric pallet stackers, on the other hand, use electric motors to lift and move the pallet, providing more power and ease of operation.
Picking Pallets Off the Ground with a Pallet Stacker
Picking up pallets from the ground can be a tricky process with a pallet stacker, particularly in environments with uneven surfaces or when working with heavy pallets. Here are some best practices for picking pallets off the ground safely and effectively:

1. Check the Ground Surface
   Before attempting to pick up a pallet, always ensure that the surface you are working on is even and stable. Uneven or sloped surfaces can make it more difficult to stabilize the stacker, increasing the risk of accidents or machine malfunctions. If you are working in a warehouse with a concrete floor, make sure there are no obstacles or debris that could obstruct the stacker's movement.
   
2. Position the Stacker Correctly
   Align the forks of the pallet stacker with the bottom of the pallet. The forks should be placed under the pallet’s bottom deck boards and as close to the middle as possible to ensure proper balance. You want to avoid lifting a pallet from the edge or overextending the forks, which can lead to instability when the pallet is lifted.
   
3. Use the Correct Lifting Method
   To lift the pallet, ensure you engage the stacker’s lifting mechanism properly. For a manual stacker, pump the handle slowly and steadily to raise the forks. With an electric stacker, press the appropriate button or lever to lift the forks, ensuring that the lift happens smoothly without jerking or sudden movements.
   
4. Lift Gradually and Steadily
   When lifting the pallet, make sure to lift it gradually and steadily to prevent any shifting or tipping of the load. A sudden, jerky motion can cause the pallet to become unbalanced and fall off the stacker. When using an electric pallet stacker, always monitor the load as it rises to make sure it stays level.
   
5. Transporting the Pallet
   Once the pallet is lifted, drive the stacker to its destination. Always drive in straight lines and avoid sharp turns. When traveling with a load, it’s important to keep the pallet as low to the ground as possible to improve stability and prevent tipping. If you are using a manual stacker, make sure to walk slowly and carefully to prevent accidents.
   
6. Lowering the Pallet
   When you reach your destination, lower the pallet carefully. For a manual stacker, gently lower the forks by releasing the control lever. For electric stackers, use the lowering control to bring the pallet down in a controlled manner. Make sure the pallet is fully on the ground before releasing the stacker.
   

Challenges of Picking Pallets Off the Ground
While pallet stackers are highly effective, there are certain challenges operators may encounter when picking pallets off the ground. Some of the common issues include:

1. Uneven Ground or Obstructions
   Working in areas with uneven flooring, potholes, or obstructions can make it difficult to properly position the pallet stacker. In these cases, it may be necessary to use a different type of equipment, such as a forklift or a pallet jack, especially for heavier pallets.
   
2. Heavy or Overloaded Pallets
   Pallet stackers are designed for a range of weights, but there are limitations. Trying to lift a pallet that exceeds the stacker’s weight capacity can damage the equipment and pose a risk to the operator. Always verify the load capacity of your pallet stacker before using it to lift heavy pallets. For extremely heavy loads, consider using a forklift or an industrial lifting machine.
   
3. Stacker Stability
   Stability is a major concern when picking up pallets, especially from the ground. Since the pallet stacker has a higher center of gravity when lifting, there is a risk of tipping if the load is uneven or the machine is not properly balanced. Make sure to inspect the stacker’s wheels, forks, and lifting mechanisms before operation.
   

Safety Tips for Using a Pallet Stacker
As with any heavy equipment, safety is paramount when using a pallet stacker. Here are some key safety tips to ensure safe operation:

1. Wear Proper PPE: Operators should always wear appropriate Personal Protective Equipment (PPE), including gloves, steel-toe boots, and high-visibility clothing. In some cases, operators may also need hearing protection if the equipment generates significant noise.
   
2. Inspect the Equipment: Before using a pallet stacker, conduct a thorough pre-operation inspection. Check the stacker’s forks, hydraulic system, battery charge (if electric), and wheels for any signs of wear or damage. A faulty pallet stacker can lead to accidents or equipment breakdown.
   
3. Avoid Overloading: Always ensure that the pallet stacker’s load capacity is not exceeded. Overloading can lead to tipping, poor stability, and damage to the stacker. Make sure the load is evenly distributed on the forks to minimize the risk.
   
4. Keep Aisles Clear: Ensure that pathways are clear of obstacles so that the stacker can move safely through the space. Avoid running into other equipment, shelves, or materials while moving the pallet.
   
5. Watch for Pedestrians: In warehouse environments, there may be other workers walking or operating equipment. Always ensure that you have a clear path and communicate with others to avoid accidents.
   

Real-World Example: A Warehouse with Limited Space
A warehouse manager in New Jersey shared a story about how their facility used pallet stackers to improve efficiency in a crowded area with limited space. The warehouse had a narrow aisle where a forklift couldn't easily maneuver. The team used electric pallet stackers to lift and move pallets between the shelves without disturbing other workers or equipment. The ability to pick up pallets from the ground and maneuver in tight spaces significantly improved the productivity of their operation. The warehouse manager credited the manual checks on pallet stability and regular maintenance for keeping the equipment in optimal working condition.
Conclusion: Maximizing Efficiency with Pallet Stackers
Picking pallets off the ground with a pallet stacker is an essential skill in the world of material handling, especially when space is limited or the weight of the load is moderate. By following proper techniques, maintaining equipment, and prioritizing safety, operators can ensure smooth, efficient operations while avoiding potential accidents or equipment damage.
While a pallet stacker is ideal for many tasks, always ensure that the machine’s load capacity is respected, the work area is stable, and that all safety protocols are followed. With these best practices in mind, operators can enhance productivity and create a safer, more efficient work environment.