A pallet stacker lifts palletised loads to height — into racking, onto a stack or up to bench level — without the cost, footprint or driver training of a counterbalance forklift. But the term covers everything from a simple hand-pumped machine to a fully powered walk-behind truck, and picking the wrong type either wastes money or wears out your operators. This guide walks through how to choose a pallet stacker: the three drive types, straddle versus counterbalance designs, and the specifications that actually matter.
First: do you need a stacker at all?
If your pallets only ever travel along the floor, a pallet truck does the job for far less. A stacker earns its place the moment loads need to go up — feeding racking beams, double-stacking pallets, or loading machines and benches. If you are still weighing the two up, start with our pallet stacker vs pallet truck guide, then come back here to choose the stacker itself.
The three drive types
1. Manual hydraulic stackers
The operator raises the forks with a hand-operated hydraulic pump and pushes the stacker by hand. No battery, no charging, almost nothing to service — which makes a hydraulic stacker the lowest-cost route to lifting pallets. UK-made GPC VULCAN models carry 1,000kg to lift heights of 1,600mm, 2,500mm or 3,000mm, in fixed-fork and adjustable straddle configurations. The trade-off is effort: pumping a full load to height is hard work, so manual stackers suit occasional lifts — a few times a day, not a few times an hour.
2. Semi-electric stackers
A semi-electric stacker keeps manual push-and-steer travel but powers the lift from a 12v/150Ah battery with a built-in charger. That removes the hardest part of the job (the pumping) while staying well below the price of a fully powered truck. VULCAN semi-electric models conform to EN 1757-1, with straddle versions to EN 1757-2 offering adjustable forks and straddle legs (1,100–1,380mm overall width) driven by a 1,500W electro-hydraulic power pack. The right middle ground for regular-but-not-relentless stacking.
3. Fully powered stackers
Powered on both drive and lift, so the operator simply walks alongside and steers. On a busy goods-in or production area, a powered stacker protects your team from fatigue and speeds every cycle. The VULCAN fully powered range runs from a 600kg counterbalance model up to 2,000kg straddle stackers, with duplex masts, built-in or 3-pin-socket charging and a heavy-duty traction battery good for 8–9 hours of continuous work. If loads are heavy, lifts are frequent or shifts are long, this is the type to specify.
Straddle or counterbalance?
Independently of drive type, stackers come in two front-end designs, and pallet type decides between them.
Straddle stackers carry the load between two legs that pass either side of the pallet. That gives excellent stability at height without a heavy counterweight and keeps the machine compact — the fully powered VULCAN straddle models turn in just 1,485mm. The catch: the legs need clear space at floor level, so straddle designs suit open-bottom pallets, Euro pallets and stillages.
Counterbalance stackers use a rear counterweight instead of legs, so the forks are completely clear underneath. They can pick up closed-board pallets and drive straight up to racking without the legs fouling feet or beams. You pay for that flexibility with a larger, heavier machine and lower capacity at entry level (from 600kg).
The specifications that matter
- Capacity: rate the stacker for your heaviest regular pallet, not your average. Our range spans 600kg to 2,000kg. Remember capacity is quoted at a stated load centre — a long or unevenly loaded pallet effectively reduces it.
- Lift height: measure to your highest racking beam and add clearance to lift the pallet off it. Manual models reach 3,000mm; check the raised and lowered mast height too, so the stacker fits under doorways and mezzanines.
- Pallet type: open-bottom and Euro pallets suit straddle legs; closed-board pallets need counterbalance or adjustable-fork straddle designs.
- Duty cycle: a few lifts a day, manual; hourly lifts, semi-electric; constant work, fully powered.
- Aisle width: check the turning radius against your narrowest working aisle before you buy, not after.
- Environment: smooth, level floors are assumed for all walk-behind stackers — for yards and rough ground, look at rough-terrain pallet trucks instead.
Safety, standards and training
Stackers in our range are CE marked and conform to EN 1757 (part 1, or part 2 for selected semi-electric straddle models). In use, they fall under PUWER 1998 — so operators must be trained, even though no formal licence is required for pedestrian-operated stackers — and as lifting equipment they need a thorough examination by a competent person at least every 12 months under LOLER 1998. Keep travel with the load lowered, and never exceed the rated capacity or load centre.
Frequently asked questions
Do you need a licence to operate a pallet stacker?
No formal licence is required for pedestrian walk-behind stackers in the UK, but employers must provide adequate training under PUWER 1998, and lifting equipment must be examined at least every 12 months under LOLER 1998.
Can a pallet stacker replace a forklift?
For ground-floor stacking into standard racking at moderate heights and weights (up to 2,000kg in our range), often yes — at a fraction of the cost and without counterbalance truck training. For heavy loads, high racking, ramps or lorry loading from the ground, you still need a forklift.
What is the difference between a straddle and a counterbalance stacker?
A straddle stacker supports the load between two floor-level legs that pass either side of the pallet; a counterbalance stacker uses a rear counterweight, leaving the forks clear underneath so it can handle closed-board pallets and drive flush to racking.
How high can a pallet stacker lift?
Manual hydraulic models in our range lift to 3,000mm; semi-electric and fully powered models offer raised heights from 1,600mm upwards depending on model. Always confirm the raised and lowered mast heights against your building.
Ready to compare models? Browse the full pallet stacker range — manual, semi-electric and fully powered side by side — or get in touch and we will help you match capacity, lift height and pallet type to the right machine.